WO2013154602A1 - Method of manufacturing light emitting device - Google Patents

Method of manufacturing light emitting device Download PDF

Info

Publication number
WO2013154602A1
WO2013154602A1 PCT/US2012/053706 US2012053706W WO2013154602A1 WO 2013154602 A1 WO2013154602 A1 WO 2013154602A1 US 2012053706 W US2012053706 W US 2012053706W WO 2013154602 A1 WO2013154602 A1 WO 2013154602A1
Authority
WO
WIPO (PCT)
Prior art keywords
release film
fluorinated polymer
light emitting
cavities
mold
Prior art date
Application number
PCT/US2012/053706
Other languages
French (fr)
Inventor
David Bravet
Michael A. Adamko
Original Assignee
Saint-Gobain Performance Plastics Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saint-Gobain Performance Plastics Corporation filed Critical Saint-Gobain Performance Plastics Corporation
Priority to SG11201405896TA priority Critical patent/SG11201405896TA/en
Priority to US14/394,392 priority patent/US20150321387A1/en
Priority to EP12874175.8A priority patent/EP2837040A4/en
Priority to KR20147029853A priority patent/KR20150001766A/en
Priority to KR1020167036063A priority patent/KR20160150657A/en
Priority to CN201280071700.9A priority patent/CN104170101B/en
Priority to JP2015504540A priority patent/JP2015519728A/en
Publication of WO2013154602A1 publication Critical patent/WO2013154602A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • B29C33/68—Release sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/52—Encapsulations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14639—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles for obtaining an insulating effect, e.g. for electrical components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • B29C33/60—Releasing, lubricating or separating agents
    • B29C33/62—Releasing, lubricating or separating agents based on polymers or oligomers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0067—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other
    • B29C37/0075—Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other using release sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/003—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor characterised by the choice of material
    • B29C39/006—Monomers or prepolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14008—Inserting articles into the mould
    • B29C45/14016—Intermittently feeding endless articles, e.g. transfer films, to the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/0074—Production of other optical elements not provided for in B29D11/00009- B29D11/0073
    • B29D11/00807—Producing lenses combined with electronics, e.g. chips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
    • H01L24/93—Batch processes
    • H01L24/95—Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips
    • H01L24/97—Batch processes at chip-level, i.e. with connecting carried out on a plurality of singulated devices, i.e. on diced chips the devices being connected to a common substrate, e.g. interposer, said common substrate being separable into individual assemblies after connecting
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
    • H01L25/03—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes
    • H01L25/04—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
    • H01L25/075—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00
    • H01L25/0753—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00 the devices being arranged next to each other
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/52—Encapsulations
    • H01L33/54—Encapsulations having a particular shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C2045/0075—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping curing or polymerising by irradiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14065—Positioning or centering articles in the mould
    • B29C2045/14155—Positioning or centering articles in the mould using vacuum or suction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14754—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles being in movable or releasable engagement with the coating, e.g. bearing assemblies
    • B29C2045/1477—Removable inserts, e.g. the insert being peeled off after moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0016—Lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2327/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
    • C08J2327/02—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment
    • C08J2327/12—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
    • C08J2327/18—Homopolymers or copolymers of tetrafluoroethylene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2327/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
    • C08J2327/02—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment
    • C08J2327/12—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
    • C08J2327/20—Homopolymers or copolymers of hexafluoropropene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2329/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
    • C08J2329/10—Homopolymers or copolymers of unsaturated ethers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/42—Wire connectors; Manufacturing methods related thereto
    • H01L2224/44—Structure, shape, material or disposition of the wire connectors prior to the connecting process
    • H01L2224/45—Structure, shape, material or disposition of the wire connectors prior to the connecting process of an individual wire connector
    • H01L2224/45001—Core members of the connector
    • H01L2224/45099—Material
    • H01L2224/451—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof
    • H01L2224/45138—Material with a principal constituent of the material being a metal or a metalloid, e.g. boron (B), silicon (Si), germanium (Ge), arsenic (As), antimony (Sb), tellurium (Te) and polonium (Po), and alloys thereof the principal constituent melting at a temperature of greater than or equal to 950°C and less than 1550°C
    • H01L2224/45144—Gold (Au) as principal constituent
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/42—Wire connectors; Manufacturing methods related thereto
    • H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
    • H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
    • H01L2224/4805—Shape
    • H01L2224/4809—Loop shape
    • H01L2224/48091—Arched
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/42—Wire connectors; Manufacturing methods related thereto
    • H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
    • H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
    • H01L2224/481—Disposition
    • H01L2224/48151—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
    • H01L2224/48221—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
    • H01L2224/48245—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic
    • H01L2224/48247—Connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being metallic connecting the wire to a bond pad of the item
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/15—Details of package parts other than the semiconductor or other solid state devices to be connected
    • H01L2924/181—Encapsulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2933/00—Details relating to devices covered by the group H01L33/00 but not provided for in its subgroups
    • H01L2933/0008—Processes
    • H01L2933/0033—Processes relating to semiconductor body packages
    • H01L2933/005—Processes relating to semiconductor body packages relating to encapsulations
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Definitions

  • the present invention relates to manufacturing a light emitting device and more particularly to the use of a mold release film during the manufacture on an encapsulated light emitting diode.
  • a light emitting diode is a solid-state, semiconductor light source having a number of advantages over more traditional incandescent light bulbs and fluorescent lamps. Some of the advantages of LEDs include low power consumption, small size, faster on/off times, low heat radiation, long useful life, shock resistance, and a simple fabrication process. Production of LED devices continues to increase with increasing demand, partly driven by utilization of LED devices in new applications.
  • a conventional LED generally comprises a semiconductor chip; an encapsulant, often made of epoxy or silicone; and electrical connection elements comprising two fine gold wires bonded to the contacts and connected to two metal pins emerging from the envelope.
  • the semiconductor chip is doped to create a p-n junction so that current will flow easily from the p-side, or anode, to the n-side, or cathode, thus forming a diode. As current flows across the diode, the movement of electrons and electron holes causes the release of energy in the form of photons.
  • FIG. 1 is a diagram of a conventional LED, which includes diode 102, having the structure described above, two external electrodes 104 (connected to the cathode) and 106 (connected to the anode), and an encapsulant 110, mounted on a substrate 112.
  • the encapsulant serves several functions, including protecting the diode and electrical connections against oxidation and moisture, improving shock resistance, and acting as a diffusing element or lens for light produced by the LED.
  • FIG. 2 A typical fabrication process is shown in FIG. 2, described below, in which encapsulated LED devices are produced using multi-cavity molds to form the encapsulating lens.
  • the release film is a significant component with respect to a variety of possible manufacturing defects for such lenses.
  • ETFE ethylene tetrafluoroethylene
  • ETFE film is available only from a limited number of suppliers. Further, not all ETFE film is suitable for use as a mold release film.
  • Embodiments of the present invention thus relate to a mold release film that meets the requirements of industry in terms of yield and fabrication costs, while also enlarging the range of products available for LED fabrication.
  • a preferred embodiment of the present invention is directed to a novel method of producing an encapsulated light emitting device.
  • a preferred mold release film that can be used during the encapsulation of a LED chip has an elastic modulus and a glass transition temperature that are low enough as compared to the desired molding temperature that the release film will closely conform to the interior of the molding cavities used to form a protective lens surrounding an LED chip.
  • FIG. 1 is a diagram of a conventional prior art LED
  • FIG. 2 shows a prior art method of forming encapsulated LED devices using multi- cavity molds to form the encapsulating lens
  • FIG. 3 is a flow chart showing the steps in a method of producing an encapsulated light emitting device according to preferred embodiments of the present invention.
  • FIG. 4 shows a prior art mold that could be used to practice embodiments of the present invention.
  • Preferred embodiments of the present invention are directed at a novel method of producing an encapsulated light emitting device.
  • a typical fabrication process for LED devices involves encapsulating the LED itself within a dome-shaped lens of epoxy or silicone.
  • the encapsulating material also referred to as potting material, not only protects the LED from damage due to moisture, shock, etc., the encapsulating material must also be adequately transmit the desired wavelengths of light.
  • the degree to which light is transmitted by the encapsulant (lens) is an important consideration in choosing an encapsulating material. Unfortunately, some amount of the light generated by the LED chip will always be trapped within the encapsulating material due to the refractive index of the material and the degree of total internal reflection. This trapped light undesirably reduces or otherwise alters the light output of the LED device.
  • FIG. 2 shows a prior art method of forming encapsulated LED devices using multi- cavity molds to form the encapsulating lens.
  • the prior art method comprises providing a plurality of light emitting elements201 mounted on a support structure 202, such as an LED chip mounted on a PCB substrate.
  • a mold with an upper surface 205 and a lower surface 204 is also provided.
  • Lower surface 204 preferably has a plurality of cavities 206, with the arrangement of cavities corresponding to the arrangement of LED chips on the substrate.
  • the shape of the cavities defines the shape of the encapsulant or lens to be formed around the corresponding light emitting elements.
  • the cavities are shaped to produce a dome- shaped lens, such as the one shown in FIG.l.
  • the substrate, such as the PCB is fixed in place (usually by application of a vacuum) on the upper mold surface with the LED chips facing the cavities in the lower half of the mold.
  • the cavities 206 are then covered by a flexible sacrificial mold release film 208, which serves to prevent the encapsulating material from adhering to the inside of the mold cavities, thus allowing the mold to be re -used, and also to prevent damage to the lens when the lens and mold are separated.
  • the release film is conformed to the inside of the cavities, usually by the application of a vacuum through a vacuum pathway 210 in each cavity. Once the vacuum is applied, the release film will be pulled into the cavities to completely cover the interior surface of the cavities.
  • One common release film used in the prior art is formed from the fluoropolymer ETFE.
  • the release film can be supplied from a roll 212 of unused release film, with the used release film wound onto a take-up reel 214.
  • an encapsulating material 218 (also referred to as a potting material) is introduced into the cavities.
  • Typical encapsulating materials include epoxies and silicone resin.
  • the LED chips or other light emitting devices 201 are then pressed into the encapsulating material so that the encapsulating material 218 fills all of the space inside the cavities 206.
  • the mold is then clamped and heated (for example, to 100- 150°C for 3-10 minutes) to cure the encapsulant material.
  • the mold can then be released and the encapsulated LED devices 220 removed from the mold.
  • the used release film can be removed from the cavities, usually by winding the used film onto the take-off roller 214 while a continuous portion of unused film 208 is rolled over the cavities so that the encapsulation process can be repeated.
  • Molding equipment suitable for carrying out the process of FIG. 2 is available, for example, from TOWA Corporation of Kyoto, Japan; high-brightness LED chips are available, for example, from Lextar Electronics Corporation of Hsinchu, Taiwan; and suitable silicone resin for use as an encapsulating material is available, for example, from Dow Corning of Midland, MI, US.
  • the release film plays a surprisingly important role in the fabrication of encapsulated light emitting devices, especially in regard to reducing manufacturing failures and maintaining commercially acceptable yields for the
  • Failures related to release film can include peeling and/or crumbling of the lens surface after demolding.
  • observed defects can include deformation of the lens, sometimes referred to as a "cat-eye” defect because the distorted lens shape often resembles a cat's eye rather than the intended clear dome shape.
  • a preferred mold release film according to the present invention will thus have an elastic modulus (E) at the mold temperatures that is low enough for the preferred material to be elastic enough to conform completely to the inside of the cavities.
  • a preferred mold release film will have an elastic modulus at 150°C of no more than 50MPa, more preferably no more than 35 MPa, even more preferably no more than 30 MPa, and still more preferably no more than 25 MPa.
  • a preferred mold release film according to the present invention will have a glass transition temperature (T g ) that is low enough for the material to have reached the rubber plateau, but not so low that the material reaches its melting point.
  • a preferred mold release film will have a glass transition temperature of less than 100°C, more preferably less than 90°C, but with a melting point above the highest operating temperature of the mold, for example above 200°C. Additionally, Applicants believe that contact angle with water is also a significant characteristic of a preferred mold release film. Generally speaking, the higher the contact angle, the lower the surface energy of the release film and the lower the ability of the film to interact with or adhere to the encapsulant.
  • a preferred mold release film will have a contact angle of at least 93 degrees, more preferably of at least 95 degrees. The adhesion forces between the release film and the encapsulant will also be minimized by using a film having a lower surface energy.
  • the surface energy of ETFE is approximately 25 dynes/cm.
  • a preferred release film according to some embodiments of the present invention will have a surface energy that is less than 25 dynes/cm, more preferably less than 20 dynes/cm.
  • a mold release film according to the present invention preferably has a tensile strength of greater than 20 MPa and an elongation-at-break at 150°C of greater than 200%. This provides the mold release film with a sufficient amount of strength and resiliency so that even when the film is deformed (as when it in conformed to the interior of the cavities) cracking, tearing, and overstretching can be prevented.
  • a preferred mold release film will be thick enough that the film will be strong enough to avoid being unduly damaged during the manufacturing process even where the tensile strength and elongation-at- break are as described above.
  • An example of a suitable thickness would be at least 3 mils.
  • the mold release film have a surface that is as smooth as possible in order to produce a lens having a surface that is as smooth as possible.
  • a rougher surface on the LED lens can contribute to light scattering, which can reduce the effectiveness of an LED light source.
  • a preferred mold release film will have an average surface roughness (Sa) of 0.20 ⁇ or less, more preferably of 0.15 ⁇ or less, and even more preferably ofO.lO ⁇ or less.
  • MFA perfluoroalkoxy polymers
  • TFE tetrafluoroethylene
  • MFA has an elastic modulus at 150°C of 17.3 MPa, and a glass transition temperature of approximately 86.7°C. Based upon testing done by Applicants, a preferred mold release film formed from MFA is capable of conforming very closely to the interior of a mold cavity.
  • FEP fluorinated ethylene propylene
  • FIG. 4 is a flow chart showing the steps in a method of producing an encapsulated light emitting device according to preferred embodiments of the present invention.
  • the materials and steps for practicing preferred embodiments of the present invention are the same as for the prior art process described in FIG. 2 with the exception of the novel mold release film used.
  • the manufacturing operation begins in step 400.
  • step 401 a plurality of non-encapsulated light emitting elements mounted on a support structure is provided.
  • an LED chip mounted on a PCB substrate is used.
  • the LED chip can be of any type or color.
  • Embodiments of the present invention are also suitable for use with high-brightness LEDs. Although this method could be practiced using a single light emitting element, in most cases a large number of LEDs would be processed simultaneously.
  • a mold having a plurality of cavities that define a shape of an encapsulant to be formed around the light emitting element is provided.
  • the cavities will produce a dome-shaped lens, such as the one shown in FIG. 1, but any desired shape could be used.
  • the arrangement of LED devices on the substrate should correspond to the arrangement of cavities in the lower half of the mold so that each LED can be placed in a separate cavity.
  • the substrate, such as the PCB is then fixed in place (usually by application of a vacuum) on the upper mold surface in step 403 with the LED chips facing the cavities in the lower half of the mold.
  • An example of the lower portion of a mold 504 suitable for use with embodiments of the present invention is shown in FIG. 5.
  • Lower mold portion 504 has cavities for forming two different sizes of LED lenses. For example, larger cavities 550 could be used to form lenses having a diameter of 2.5 mm, while smaller cavities 552 could be used to form lenses having a diameter of 1.8 mm.
  • a release film is provided and placed over the cavities, a preferred release film according to embodiments of the present invention comprising a fully fluorinated polymer, such as, for example, a perfluoroalkoxy polymer, including MFA, or fluorinated ethylene propylene.
  • the mold release film is conformed to the inside of the cavities, preferably by was of a vacuum pressure applied to each cavity that pulls the release film down into each of the cavities.
  • an encapsulating material such as a resin (potting material) is introduced into each of the cavities.
  • a resin potting material
  • the encapsulating material can be injected into the cavities of the lower half of the mold from a runner or nozzle.
  • the release film fitting to the interior walls of the cavities prevents the encapsulating material from contacting the interior of the cavities.
  • step 410 the light emitting elements are positioned so that they are within the cavities and surrounded by the encapsulating material. This can be accomplished by closing the mold, which causes the light emitting elements (such as LED chips) to be pressed down into the encapsulating material, thus causing the encapsulating material to fill the cavities.
  • step 412 the mold is then clamped and heated (for example, to 100-150°C for 3-10 minutes) to cure the encapsulant material. Once the cure is complete, in step 414, the mold can then be released and the encapsulated LED device removed from the mold. If additional LEDs are to be encapsulated 416, the process returns to step 401; if not, the manufacturing process is terminated in step 418.
  • a preferred embodiment of the present invention is thus directed at a method of producing an encapsulated light emitting device, the method comprising:
  • the release film comprising a fully fluorinated polymer
  • a method of manufacturing a light emitting device including a light emitting element encapsulated by a resin lens comprises:
  • the release film comprising a perfluoroalkoxy polymer or fluorinated ethylene propylene
  • an apparatus for manufacturing a light emitting device comprises:
  • a mold having a plurality of cavities that define a lens shape
  • winding reels for scrolling a mold release film over the plurality of cavities; a dispenser for introducing a silicone resin into the plurality of cavities; a vacuum system for applying a vacuum to the plurality of cavities to form the release film to the interior of the cavities; and
  • a method of producing an encapsulated light emitting device comprises:
  • a mold having a plurality of cavities that define a shape of an encapsulant to be formed from a heat-curable resin around the light emitting element; providing a release film covering the cavities, the release film selected from a group of fluorinated polymers having an elastic modulus of 50 MPa or less at 150°C, a glass transition temperature that is below the curing temperature of the heat-curable resin, a contact angle with water of at least 95 degrees, and a surface energy that is less than 25 dynes/cm;
  • the light emitting device can comprise a light emitting diode (LED), a visible light LED, a through-hole LED, a surface mount LED, a high-brightness LED, or an organic LED.
  • the resin or potting material can comprise an epoxy or silicone.
  • conforming the release film to the interior of the cavities can comprise applying a vacuum to the cavities through a vacuum port to fit the release film to the interior of the cavities.
  • the fluorinated polymer can comprise perfluoro methyl alkoxy (MFA), fluorinated ethylene propylene (FEP), and/or a perfluoroalkoxy polymer formed from polymerization of at least tetrafluoroethylene (TFE) and perfluoromethyl vinyl ether (PMVE).
  • the fluorinated polymer can have a contact angle with water of at least 93 degrees or a contact angle with water of at least 95 degrees.
  • the fluorinated polymer can have an elastic modulus at 150°C of no more than 50MPa, no more than 35 MPa, no more than 30 MPa, or no more than 25 MPa.
  • the fluorinated polymer has a glass transition temperature of less than 100°C or less than 90°C and a surface energy that is less than 25 dynes/cm or less than 20 dynes/cm.
  • the release film comprises a fluorinated polymer has an average surface roughness of 0.20 ⁇ or less, an average surface roughness of 0.15 ⁇ or less, or an average surface roughness of 0.10 ⁇ or less.
  • the release film can also comprise a roll of fully fluorinated polymer film, the fully fluorinated polymer having a melting temperature of greater than 200°C, a tensile strength of 20 MPa or greater, and an elongation-at-break at 150°C of greater than 300%.
  • the release film comprises a fully fluorinated polymer having an elastic modulus at 150°C of no more than 50MPa, no more than 35 MPa, no more than 30 MPa, or no more than 25 MPa.
  • the release film comprises a fully fluorinated polymer having a glass transition temperature of less than 100°C or less than 90°C.
  • the release film can also comprise a fully fluorinated polymer having an average surface roughness of 0.20 ⁇ or less, an average surface roughness of 0.15 ⁇ or less, or an average surface roughness of 0.10 ⁇ or less.
  • the release film can also comprise a fully fluorinated polymer having a surface energy that is less than 25 dynes/cm or less than 20 dynes/cm.
  • the fully fluorinated polymer comprises MFA or FEP.
  • a mold release film for use in molding a silicon lens to encapsulate a light emitting diode
  • the mold release film comprises a fluorinated polymer film having a glass transition temperature of less than 100°C; an elastic modulus at 150°C of no more than 50MPa; and an average surface roughness of 0.20 ⁇ or less.
  • the fluorinated polymer film has a glass transition temperature of less than 90°C.
  • the fluorinated polymer film can have an elastic modulus at 150°C of no more than 35 MPa, no more than 30 MPa, or no more than 25 MPa.
  • the fluorinated polymer film can have an average surface roughness of 0.15 ⁇ or less, or 0.10 ⁇ or less.
  • the fluorinated polymer film can comprise a fully fluorinated thermoplastic polymer film.
  • the fluorinated polymer film has a contact angle with water of at least 93 degrees, or of at least 95 degrees.
  • the fluorinated polymer film can comprise a perfluoroalkoxy polymer formed from polymerization of at least
  • the release film as described in any of the specific embodiments above, can have a thickness of no more than 3 mils.
  • Preferred embodiments of the present invention also include a light emitting device made by any of the methods described herein.
  • the invention described herein has broad applicability and can provide many benefits as described and shown in the examples above. The embodiments will vary greatly depending upon the specific application, and not every embodiment will provide all of the benefits and meet all of the objectives that are achievable by the invention.
  • Release film material suitable for carrying out the present invention, such as MFA, is commercially available, for example, from the assignee of the present application.

Landscapes

  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Power Engineering (AREA)
  • Computer Hardware Design (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
  • Led Device Packages (AREA)
  • Encapsulation Of And Coatings For Semiconductor Or Solid State Devices (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

A novel method of producing an encapsulated light emitting device. A preferred mold release film that can be used during the encapsulation of a LED chip has an elastic modulus and a glass transition temperature that are low enough as compared to the desired molding temperature that the release film will closely conform to the interior of the molding cavities used to form a protective lens surrounding an LED chip. A preferred release film according to embodiments of the present invention comprises a fully fluorinated polymer, such as a perfluoroalkoxy polymer, including MFA, or fluorinated ethylene propylene.

Description

METHOD OF MANUFACTURING LIGHT EMITTING DEVICE
Technical Field of the Invention
The present invention relates to manufacturing a light emitting device and more particularly to the use of a mold release film during the manufacture on an encapsulated light emitting diode.
Background of the Invention
A light emitting diode (LED) is a solid-state, semiconductor light source having a number of advantages over more traditional incandescent light bulbs and fluorescent lamps. Some of the advantages of LEDs include low power consumption, small size, faster on/off times, low heat radiation, long useful life, shock resistance, and a simple fabrication process. Production of LED devices continues to increase with increasing demand, partly driven by utilization of LED devices in new applications.
A conventional LED generally comprises a semiconductor chip; an encapsulant, often made of epoxy or silicone; and electrical connection elements comprising two fine gold wires bonded to the contacts and connected to two metal pins emerging from the envelope. The semiconductor chip is doped to create a p-n junction so that current will flow easily from the p-side, or anode, to the n-side, or cathode, thus forming a diode. As current flows across the diode, the movement of electrons and electron holes causes the release of energy in the form of photons.
FIG. 1 is a diagram of a conventional LED, which includes diode 102, having the structure described above, two external electrodes 104 (connected to the cathode) and 106 (connected to the anode), and an encapsulant 110, mounted on a substrate 112. The encapsulant serves several functions, including protecting the diode and electrical connections against oxidation and moisture, improving shock resistance, and acting as a diffusing element or lens for light produced by the LED.
A typical fabrication process is shown in FIG. 2, described below, in which encapsulated LED devices are produced using multi-cavity molds to form the encapsulating lens. Applicants have discovered that the release film is a significant component with respect to a variety of possible manufacturing defects for such lenses. It is known to use ethylene tetrafluoroethylene (ETFE) film as a mold release film for LED encapsulation. However, ETFE film is available only from a limited number of suppliers. Further, not all ETFE film is suitable for use as a mold release film.
What is needed is an alternative mold release film for use during LED encapsulation and fabrication. Embodiments of the present invention thus relate to a mold release film that meets the requirements of industry in terms of yield and fabrication costs, while also enlarging the range of products available for LED fabrication.
Summary of the Invention
A preferred embodiment of the present invention is directed to a novel method of producing an encapsulated light emitting device. A preferred mold release film that can be used during the encapsulation of a LED chip has an elastic modulus and a glass transition temperature that are low enough as compared to the desired molding temperature that the release film will closely conform to the interior of the molding cavities used to form a protective lens surrounding an LED chip.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
Brief Description of the Drawin2S
For a more thorough understanding of the present invention, and advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagram of a conventional prior art LED;
FIG. 2 shows a prior art method of forming encapsulated LED devices using multi- cavity molds to form the encapsulating lens;
FIG. 3 is a flow chart showing the steps in a method of producing an encapsulated light emitting device according to preferred embodiments of the present invention; and
FIG. 4 shows a prior art mold that could be used to practice embodiments of the present invention.
The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing.
Detailed Description of Preferred Embodiments
Preferred embodiments of the present invention are directed at a novel method of producing an encapsulated light emitting device. A typical fabrication process for LED devices involves encapsulating the LED itself within a dome-shaped lens of epoxy or silicone. The encapsulating material, also referred to as potting material, not only protects the LED from damage due to moisture, shock, etc., the encapsulating material must also be adequately transmit the desired wavelengths of light. The degree to which light is transmitted by the encapsulant (lens) is an important consideration in choosing an encapsulating material. Unfortunately, some amount of the light generated by the LED chip will always be trapped within the encapsulating material due to the refractive index of the material and the degree of total internal reflection. This trapped light undesirably reduces or otherwise alters the light output of the LED device.
FIG. 2 shows a prior art method of forming encapsulated LED devices using multi- cavity molds to form the encapsulating lens. First, the prior art method comprises providing a plurality of light emitting elements201 mounted on a support structure 202, such as an LED chip mounted on a PCB substrate. A mold with an upper surface 205 and a lower surface 204 is also provided. Lower surface 204 preferably has a plurality of cavities 206, with the arrangement of cavities corresponding to the arrangement of LED chips on the substrate. The shape of the cavities defines the shape of the encapsulant or lens to be formed around the corresponding light emitting elements. Typically, the cavities are shaped to produce a dome- shaped lens, such as the one shown in FIG.l. The substrate, such as the PCB, is fixed in place (usually by application of a vacuum) on the upper mold surface with the LED chips facing the cavities in the lower half of the mold.
The cavities 206 are then covered by a flexible sacrificial mold release film 208, which serves to prevent the encapsulating material from adhering to the inside of the mold cavities, thus allowing the mold to be re -used, and also to prevent damage to the lens when the lens and mold are separated. The release film is conformed to the inside of the cavities, usually by the application of a vacuum through a vacuum pathway 210 in each cavity. Once the vacuum is applied, the release film will be pulled into the cavities to completely cover the interior surface of the cavities. One common release film used in the prior art is formed from the fluoropolymer ETFE. The release film can be supplied from a roll 212 of unused release film, with the used release film wound onto a take-up reel 214.
Next, an encapsulating material 218 (also referred to as a potting material) is introduced into the cavities. Typical encapsulating materials include epoxies and silicone resin. Under a partial vacuum, the LED chips or other light emitting devices 201 are then pressed into the encapsulating material so that the encapsulating material 218 fills all of the space inside the cavities 206. The mold is then clamped and heated (for example, to 100- 150°C for 3-10 minutes) to cure the encapsulant material. The mold can then be released and the encapsulated LED devices 220 removed from the mold. The used release film can be removed from the cavities, usually by winding the used film onto the take-off roller 214 while a continuous portion of unused film 208 is rolled over the cavities so that the encapsulation process can be repeated.
Molding equipment suitable for carrying out the process of FIG. 2 is available, for example, from TOWA Corporation of Kyoto, Japan; high-brightness LED chips are available, for example, from Lextar Electronics Corporation of Hsinchu, Taiwan; and suitable silicone resin for use as an encapsulating material is available, for example, from Dow Corning of Midland, MI, US.
Applicants have discovered that the release film plays a surprisingly important role in the fabrication of encapsulated light emitting devices, especially in regard to reducing manufacturing failures and maintaining commercially acceptable yields for the
manufacturing process. Failures related to release film can include peeling and/or crumbling of the lens surface after demolding. In some cases, observed defects can include deformation of the lens, sometimes referred to as a "cat-eye" defect because the distorted lens shape often resembles a cat's eye rather than the intended clear dome shape. These types of defects in encapsulated LED lenses are seen even with prior art ETFE release films. Such defects affect the light transmission of an encapsulated LED and can render it unusable. Obviously, a high yield rate (low incidence of failures) is very desirable from a commercial standpoint.
Although such defects have long been observed during encapsulated LED
manufacturing, Applicants now believe that the source of these defects is poor conformity of the release film to the mold cavity. Applicants have also discovered that characteristics like tensile strength and dimensional stability surprisingly do not appear to have a strong correlation to observed lens defects. Instead, Applicants believe that the elastic modulus and glass transition temperatures are more significant factors. Applicants note, however, that although a theoretical basis for the success of the invention is described herein, the invention has been shown to work for the release film polymers described below, regardless of the accuracy of the theory.
A preferred mold release film according to the present invention will thus have an elastic modulus (E) at the mold temperatures that is low enough for the preferred material to be elastic enough to conform completely to the inside of the cavities. A preferred mold release film will have an elastic modulus at 150°C of no more than 50MPa, more preferably no more than 35 MPa, even more preferably no more than 30 MPa, and still more preferably no more than 25 MPa. Additionally, a preferred mold release film according to the present invention will have a glass transition temperature (Tg) that is low enough for the material to have reached the rubber plateau, but not so low that the material reaches its melting point. A preferred mold release film will have a glass transition temperature of less than 100°C, more preferably less than 90°C, but with a melting point above the highest operating temperature of the mold, for example above 200°C. Additionally, Applicants believe that contact angle with water is also a significant characteristic of a preferred mold release film. Generally speaking, the higher the contact angle, the lower the surface energy of the release film and the lower the ability of the film to interact with or adhere to the encapsulant. A preferred mold release film will have a contact angle of at least 93 degrees, more preferably of at least 95 degrees. The adhesion forces between the release film and the encapsulant will also be minimized by using a film having a lower surface energy. The surface energy of ETFE, a commonly used release film for LED lens manufacturing, is approximately 25 dynes/cm. A preferred release film according to some embodiments of the present invention will have a surface energy that is less than 25 dynes/cm, more preferably less than 20 dynes/cm.
Although less significant from the perspective of solving the problem of the previously unexplained encapsulation failures, there are also a number of other characteristics that are desirable for a release film according to the present invention. As an example, a mold release film according to the present invention preferably has a tensile strength of greater than 20 MPa and an elongation-at-break at 150°C of greater than 200%. This provides the mold release film with a sufficient amount of strength and resiliency so that even when the film is deformed (as when it in conformed to the interior of the cavities) cracking, tearing, and overstretching can be prevented. Also, for the same reasons, a preferred mold release film will be thick enough that the film will be strong enough to avoid being unduly damaged during the manufacturing process even where the tensile strength and elongation-at- break are as described above. An example of a suitable thickness would be at least 3 mils.
Finally, Applicants have also determined that it is desirable that the mold release film have a surface that is as smooth as possible in order to produce a lens having a surface that is as smooth as possible. As discussed above, a rougher surface on the LED lens can contribute to light scattering, which can reduce the effectiveness of an LED light source. A preferred mold release film will have an average surface roughness (Sa) of 0.20 μιη or less, more preferably of 0.15 μιη or less, and even more preferably ofO.lO μιη or less.
One exemplary group of materials that matches desired characteristics discussed above and which could be formed into a suitable mold release film would include certain fully fluorinated thermoplastic polymers such as perfluoroalkoxy polymers, specifically perfluoro methyl alkoxy (MFA). MFA comprises a perfluoroalkoxy polymer formed from polymerization of at least tetrafluoroethylene (TFE) and perfluoromethyl vinyl ether
(PMVE). With respect to the preferred characteristics described above, MFA has an elastic modulus at 150°C of 17.3 MPa, and a glass transition temperature of approximately 86.7°C. Based upon testing done by Applicants, a preferred mold release film formed from MFA is capable of conforming very closely to the interior of a mold cavity.
Another example of a suitable fully fluorinated thermoplastic polymer would be fluorinated ethylene propylene (FEP). With respect to the preferred characteristics described above, FEP has an elastic modulus at 150°C of 48-50 MPa, and a glass transition temperature of approximately 70°C to 140°C, depending on the exact resin being tested. Based these values, a preferred mold release film formed from FEP would also be capable of conforming very closely to the interior of a mold cavity. The following chart summarizes other relevant characteristics of MFA and FEP (although measured values may vary to some degree for different manufacturers or grades).
Figure imgf000011_0001
FIG. 4 is a flow chart showing the steps in a method of producing an encapsulated light emitting device according to preferred embodiments of the present invention. The materials and steps for practicing preferred embodiments of the present invention are the same as for the prior art process described in FIG. 2 with the exception of the novel mold release film used. In the method of FIG. 4, the manufacturing operation begins in step 400. Next, in step 401, a plurality of non-encapsulated light emitting elements mounted on a support structure is provided. In preferred embodiments of the present invention, an LED chip mounted on a PCB substrate is used. The LED chip can be of any type or color.
Embodiments of the present invention are also suitable for use with high-brightness LEDs. Although this method could be practiced using a single light emitting element, in most cases a large number of LEDs would be processed simultaneously.
In step 402, a mold having a plurality of cavities that define a shape of an encapsulant to be formed around the light emitting element is provided. Typically, the cavities will produce a dome-shaped lens, such as the one shown in FIG. 1, but any desired shape could be used. As with FIG. 2 above, the arrangement of LED devices on the substrate should correspond to the arrangement of cavities in the lower half of the mold so that each LED can be placed in a separate cavity. The substrate, such as the PCB, is then fixed in place (usually by application of a vacuum) on the upper mold surface in step 403 with the LED chips facing the cavities in the lower half of the mold. An example of the lower portion of a mold 504 suitable for use with embodiments of the present invention is shown in FIG. 5. Lower mold portion 504 has cavities for forming two different sizes of LED lenses. For example, larger cavities 550 could be used to form lenses having a diameter of 2.5 mm, while smaller cavities 552 could be used to form lenses having a diameter of 1.8 mm.
In step 404, a release film is provided and placed over the cavities, a preferred release film according to embodiments of the present invention comprising a fully fluorinated polymer, such as, for example, a perfluoroalkoxy polymer, including MFA, or fluorinated ethylene propylene. In step 406, the mold release film is conformed to the inside of the cavities, preferably by was of a vacuum pressure applied to each cavity that pulls the release film down into each of the cavities. Next, in step 408, an encapsulating material such as a resin (potting material) is introduced into each of the cavities. In some preferred
embodiments, the encapsulating material can be injected into the cavities of the lower half of the mold from a runner or nozzle. The release film fitting to the interior walls of the cavities prevents the encapsulating material from contacting the interior of the cavities.
In step 410, the light emitting elements are positioned so that they are within the cavities and surrounded by the encapsulating material. This can be accomplished by closing the mold, which causes the light emitting elements (such as LED chips) to be pressed down into the encapsulating material, thus causing the encapsulating material to fill the cavities. In step 412, the mold is then clamped and heated (for example, to 100-150°C for 3-10 minutes) to cure the encapsulant material. Once the cure is complete, in step 414, the mold can then be released and the encapsulated LED device removed from the mold. If additional LEDs are to be encapsulated 416, the process returns to step 401; if not, the manufacturing process is terminated in step 418.
A preferred embodiment of the present invention is thus directed at a method of producing an encapsulated light emitting device, the method comprising:
providing a plurality of non-encapsulated light emitting elements mounted on a support structure;
providing a mold having a plurality of cavities that define a shape of an encapsulant to be formed around the light emitting element;
providing a release film covering the cavities, the release film comprising a fully fluorinated polymer;
conforming the release film to the interior of the cavities;
introducing a potting material into the space within the cavities, the release film preventing the potting material from contacting the interior of the cavities;
positioning the non-encapsulated light emitting elements so that they are within the cavities and surrounded by the potting material;
curing the potting material in the space between the light emitting elements and the release film in the cavities to encapsulate the light emitting elements; and
freeing the encapsulated light emitting elements from the mold and the release film. According to another preferred embodiment, a method of manufacturing a light emitting device including a light emitting element encapsulated by a resin lens comprises:
providing a light emitting element mounted on a support structure;
providing a mold having a cavity that defines a shape of a lens to be formed around the light emitting element;
providing a release film covering the cavity, the release film comprising a perfluoroalkoxy polymer or fluorinated ethylene propylene;
conforming the release film to the interior of the cavity;
introducing a resin into the space within the cavity, the release film preventing the resin from contacting the interior of the cavity;
positioning the light emitting element so that it is within the cavity and surrounded by the resin;
curing the resin in the space between the light emitting element and the release film in the cavity to form a lens encapsulating the light emitting element; and
freeing the light emitting device from the mold and the release film.
According to another preferred embodiment, an apparatus for manufacturing a light emitting device comprises:
a mold having a plurality of cavities that define a lens shape;
winding reels for scrolling a mold release film over the plurality of cavities; a dispenser for introducing a silicone resin into the plurality of cavities; a vacuum system for applying a vacuum to the plurality of cavities to form the release film to the interior of the cavities; and
a supply of a mold release film, the mold release film comprising a roll of a fully fluorinated polymer film. According to another preferred embodiment, a method of producing an encapsulated light emitting device comprises:
providing a plurality of non-encapsulated light emitting elements mounted on a support structure;
providing a mold having a plurality of cavities that define a shape of an encapsulant to be formed from a heat-curable resin around the light emitting element; providing a release film covering the cavities, the release film selected from a group of fluorinated polymers having an elastic modulus of 50 MPa or less at 150°C, a glass transition temperature that is below the curing temperature of the heat-curable resin, a contact angle with water of at least 95 degrees, and a surface energy that is less than 25 dynes/cm;
conforming the release film to the interior of the cavities;
introducing a heat-curable resin into the space within the cavities, the release film preventing the potting material from contacting the interior of the cavities;
positioning the non-encapsulated light emitting elements so that they are within the cavities and surrounded by the heat-curable resin;
curing the heat-curable resin in the space between the light emitting elements and the release film in the cavities by heating the mold to the curing temperature of the resin; and
freeing the encapsulated light emitting elements from the mold and the release film.
In preferred embodiments of the present invention the light emitting device can comprise a light emitting diode (LED), a visible light LED, a through-hole LED, a surface mount LED, a high-brightness LED, or an organic LED. Also, the resin or potting material can comprise an epoxy or silicone.
In preferred embodiments of the present invention conforming the release film to the interior of the cavities can comprise applying a vacuum to the cavities through a vacuum port to fit the release film to the interior of the cavities.
In preferred embodiments of the present invention the fluorinated polymer can comprise perfluoro methyl alkoxy (MFA), fluorinated ethylene propylene (FEP), and/or a perfluoroalkoxy polymer formed from polymerization of at least tetrafluoroethylene (TFE) and perfluoromethyl vinyl ether (PMVE). Also, the fluorinated polymer can have a contact angle with water of at least 93 degrees or a contact angle with water of at least 95 degrees. The fluorinated polymer can have an elastic modulus at 150°C of no more than 50MPa, no more than 35 MPa, no more than 30 MPa, or no more than 25 MPa. The fluorinated polymer has a glass transition temperature of less than 100°C or less than 90°C and a surface energy that is less than 25 dynes/cm or less than 20 dynes/cm.
In preferred embodiments of the present invention the release film comprises a fluorinated polymer has an average surface roughness of 0.20 μιη or less, an average surface roughness of 0.15 μιη or less, or an average surface roughness of 0.10 μιη or less. The release film can also comprise a roll of fully fluorinated polymer film, the fully fluorinated polymer having a melting temperature of greater than 200°C, a tensile strength of 20 MPa or greater, and an elongation-at-break at 150°C of greater than 300%. In preferred
embodiments, the release film comprises a fully fluorinated polymer having an elastic modulus at 150°C of no more than 50MPa, no more than 35 MPa, no more than 30 MPa, or no more than 25 MPa. In preferred embodiments, the release film comprises a fully fluorinated polymer having a glass transition temperature of less than 100°C or less than 90°C. The release film can also comprise a fully fluorinated polymer having an average surface roughness of 0.20 μιη or less, an average surface roughness of 0.15 μιη or less, or an average surface roughness of 0.10 μιη or less. The release film can also comprise a fully fluorinated polymer having a surface energy that is less than 25 dynes/cm or less than 20 dynes/cm. In preferred embodiments the fully fluorinated polymer comprises MFA or FEP.
Other preferred embodiments of the invention are directed at a mold release film for use in molding a silicon lens to encapsulate a light emitting diode in which the mold release film comprises a fluorinated polymer film having a glass transition temperature of less than 100°C; an elastic modulus at 150°C of no more than 50MPa; and an average surface roughness of 0.20 μιη or less. In preferred embodiments, the fluorinated polymer film has a glass transition temperature of less than 90°C. The fluorinated polymer film can have an elastic modulus at 150°C of no more than 35 MPa, no more than 30 MPa, or no more than 25 MPa. The fluorinated polymer film can have an average surface roughness of 0.15 μιη or less, or 0.10 μιη or less. The fluorinated polymer film can comprise a fully fluorinated thermoplastic polymer film. The fluorinated polymer film has a contact angle with water of at least 93 degrees, or of at least 95 degrees.
In any of the embodiments described above, the fluorinated polymer film can comprise a perfluoroalkoxy polymer formed from polymerization of at least
tetrafluoroethylene (TFE) and perfluoromethyl vinyl ether (PMVE), perfluoro methyl alkoxy (MFA), and/or fluorinated ethylene propylene (FEP). In some preferred embodiments, the release film, as described in any of the specific embodiments above, can have a thickness of no more than 3 mils.
Preferred embodiments of the present invention also include a light emitting device made by any of the methods described herein. The invention described herein has broad applicability and can provide many benefits as described and shown in the examples above. The embodiments will vary greatly depending upon the specific application, and not every embodiment will provide all of the benefits and meet all of the objectives that are achievable by the invention. Release film material suitable for carrying out the present invention, such as MFA, is commercially available, for example, from the assignee of the present application.
In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to . . . ." To the extent that any term is not specially defined in this specification, the intent is that the term is to be given its plain and ordinary meaning. The accompanying drawings are intended to aid in understanding the present invention and, unless otherwise indicated, are not drawn to scale.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made to the embodiments described herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
We claim as follows:

Claims

1. A method of producing an encapsulated light emitting device, the method comprising: providing a plurality of non-encapsulated light emitting elements mounted on a support structure;
providing a mold having a plurality of cavities that define a shape of an encapsulant to be formed around the light emitting element;
providing a release film covering the cavities, the release film comprising a fully fluorinated polymer;
conforming the release film to the interior of the cavities;
introducing a potting material into the space within the cavities, the release film preventing the potting material from contacting the interior of the cavities;
positioning the non-encapsulated light emitting elements so that they are within the cavities and surrounded by the potting material;
curing the potting material in the space between the light emitting elements and the release film in the cavities to encapsulate the light emitting elements; and
freeing the encapsulated light emitting elements from the mold and the release film.
2. A method of manufacturing a light emitting device including a light emitting element encapsulated by a resin lens, the method comprising:
providing a light emitting element mounted on a support structure;
providing a mold having a cavity that defines a shape of a lens to be formed around the light emitting element;
providing a release film covering the cavity, the release film comprising a perfluoroalkoxy polymer or fluorinated ethylene propylene;
conforming the release film to the interior of the cavity; introducing a resin into the space within the cavity, the release film preventing the resin from contacting the interior of the cavity;
positioning the light emitting element so that it is within the cavity and surrounded by the resin;
curing the resin in the space between the light emitting element and the release film in the cavity to form a lens encapsulating the light emitting element; and
freeing the light emitting device from the mold and the release film.
3. An apparatus for manufacturing a light emitting device, the apparatus comprising: a mold having a plurality of cavities that define a lens shape;
winding reels for scrolling a mold release film over the plurality of cavities;
a dispenser for introducing a silicone resin into the plurality of cavities;
a vacuum system for applying a vacuum to the plurality of cavities to form the release film to the interior of the cavities; and
a supply of a mold release film, the mold release film comprising a roll of a fully fluorinated polymer film.
4. A method of producing an encapsulated light emitting device, the method comprising: providing a plurality of non-encapsulated light emitting elements mounted on a support structure;
providing a mold having a plurality of cavities that define a shape of an encapsulant to be formed from a heat-curable resin around the light emitting element;
providing a release film covering the cavities, the release film selected from a group of fluorinated polymers having an elastic modulus of 50 MPa or less at 150°C, a glass transition temperature that is below the curing temperature of the heat-curable resin, a contact angle with water of at least 95 degrees, and a surface energy that is less than 25 dynes/cm; conforming the release film to the interior of the cavities;
introducing a heat-curable resin into the space within the cavities, the release film preventing the potting material from contacting the interior of the cavities;
positioning the non-encapsulated light emitting elements so that they are within the cavities and surrounded by the heat-curable resin;
curing the heat-curable resin in the space between the light emitting elements and the release film in the cavities by heating the mold to the curing temperature of the resin; and freeing the encapsulated light emitting elements from the mold and the release film.
5. The method of any of the preceding claims in which the light emitting device comprises a light emitting diode (LED), a visible light LED, a through-hole LED, a surface mount LED, a high-brightness LED, or an organic LED.
6. The method of any of the preceding claims in which the resin or potting material comprises an epoxy or silicone.
7. The method of any of the preceding claims in which conforming the release film to the interior of the cavities comprises applying a vacuum to the cavities through a vacuum port to fit the release film to the interior of the cavities.
8. The method of any of the preceding claims in which the fluorinated polymer comprises a perfluoroalkoxy polymer formed from polymerization of at least
tetrafluoroethylene (TFE) and perfluoromethyl vinyl ether (PMVE).
9. The method of any of the preceding claims in which the fluorinated polymer comprises perfluoro methyl alkoxy (MFA).
10. The method of any of the preceding claims in which the fluorinated polymer comprises fluorinated ethylene propylene (FEP).
11. The method of any of the preceding claims in which the fluorinated polymer has a contact angle with water of at least 93 degrees.
12. The method of any of the preceding claims in which the fluorinated polymer has a contact angle with water of at least 95 degrees.
13. The method of any of the preceding claims in which the fluorinated polymer has an elastic modulus at 150°C of no more than 50MPa.
14. The method of any of the preceding claims in which the fluorinated polymer has an elastic modulus at 150°C of no more than 35 MPa.
15. The method of any of the preceding claims in which the fluorinated polymer has an elastic modulus at 150°C of no more than 30 MPa.
16. The method of any of the preceding claims in which the fluorinated polymer has an elastic modulus at 150°C of no more than 25 MPa.
17. The method of any of the preceding claims in which the fluorinated polymer has a glass transition temperature of less than 100°C.
18. The method of any of the preceding claims in which the fluorinated polymer has a glass transition temperature of less than 90°C.
19. The method of any of the preceding claims in which the fluorinated polymer has a surface energy that is less than 25 dynes/cm.
20. The method of any of the preceding claims in which the fluorinated polymer has a surface energy that is less than 20 dynes/cm.
21. The method of any of the preceding claims in which the release film comprising a fluorinated polymer has an average surface roughness of 0.20 μιη or less.
22. The method of any of the preceding claims in which the release film comprising a fully fluorinated polymer has an average surface roughness of 0.15 μιη or less.
23. The method of any of the preceding claims in which the release film comprising a fluorinated polymer has an average surface roughness of 0.10 μιη or less.
24. A light emitting device made by the method of any of the preceding claims.
25. A mold release film for use in manufacturing a light emitting device, the release film comprising a roll of fully fluorinated polymer film, the fully fluorinated polymer having a melting temperature of greater than 200°C, a tensile strength of 20 MPa or greater, and an elongation-at-break at 150°C of greater than 300%.
26. The release film of claim 25 in which the fully fluorinated polymer has an elastic modulus at 150°C of no more than 50MPa.
27. The release film of claim 25 in which the fully fluorinated polymer has an elastic modulus at 150°C of no more than 35 MPa.
28. The release film of claim 25 in which the fully fluorinated polymer has an elastic modulus at 150°C of no more than 30 MPa.
29. The release film of claim 25 in which the fully fluorinated polymer has an elastic modulus at 150°C of no more than 25 MPa.
30. The method of any of claims 25 to 29 in which the fully fluorinated polymer has a glass transition temperature of less than 100°C.
31. The method of any of claims 25 to 29 in which the fully fluorinated polymer has a glass transition temperature of less than 90°C.
32. The method of any of claims 25 to 31 in which the release film comprising a fully fluorinated polymer has an average surface roughness of 0.20 μιη or less.
33. The method of any of claims 25 to 31 in which the release film comprising a fully fluorinated polymer has an average surface roughness of 0.15 μιη or less.
34. The method of any of claims 25 to 31 in which the release film comprising a fully fluorinated polymer has an average surface roughness of 0.10 μιη or less.
35. The method of any of claims 25 to 32 in which the fully fluorinated polymer has a surface energy that is less than 25 dynes/cm.
36. The method of any of claims 25 to 32 in which the fully fluorinated polymer has a surface energy that is less than 20 dynes/cm.
37. The method of any of claims 25 to 36 in which the fully fluorinated polymer comprises MFA or FEP.
38. A mold release film for use in molding a silicon lens to encapsulate a light emitting diode, the mold release film comprising a fluorinated polymer film having a glass transition temperature of less than 100°C; an elastic modulus at 150°C of no more than 50MPa; and an average surface roughness of 0.20 μιη or less.
39. The mold release film of claim 38 in which the fluorinated polymer film has a glass transition temperature of less than 90°C.
40. The mold release film of any of claims 25 to 39 in which the fluorinated polymer film has an elastic modulus at 150°C of no more than 35 MPa.
41. The mold release film of any of claims 25 to 39 in which the fluorinated polymer film has an elastic modulus at 150°C of no more than 30 MPa.
42. The mold release film of any of claims 25 to 39 in which the fluorinated polymer film has an elastic modulus at 150°C of no more than 25 MPa.
43. The mold release film of any of claims 25 to 42 in which the fluorinated polymer film has an average surface roughness of 0.15 μιη or less.
44. The mold release film of any of claims 25 to 42 in which the fluorinated polymer film has an average surface roughness of 0.10 μιη or less.
45. The mold release film of any of claims 25 to 44 in which the fluorinated polymer film comprises a fully fluorinated thermoplastic polymer film.
46. The mold release film of any of the preceding claims in which the release film has a thickness of no more than 3 mils.
47. The mold release film of any of claims 25 to 46 in which the fluorinated polymer film has a contact angle with water of at least 93 degrees, or of at least 95 degrees.
48. The mold release film of any of claims 25 to 47 in which the fluorinated polymer film comprises a perfluoroalkoxy polymer formed from polymerization of at least
tetrafluoroethylene (TFE) and perfluoromethyl vinyl ether (PMVE).
49. The mold release film of any of claims 25 to 47 in which the fluorinated polymer film comprises perfluoro methyl alkoxy (MFA).
50. The mold release film of any of claims 25 to 47 in which the fluorinated polymer film comprises fluorinated ethylene propylene (FEP).
PCT/US2012/053706 2012-04-12 2012-09-04 Method of manufacturing light emitting device WO2013154602A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
SG11201405896TA SG11201405896TA (en) 2012-04-12 2012-09-04 Method of manufacturing light emitting device
US14/394,392 US20150321387A1 (en) 2012-04-12 2012-09-04 Method of manufacturing light emitting device
EP12874175.8A EP2837040A4 (en) 2012-04-12 2012-09-04 Method of manufacturing light emitting device
KR20147029853A KR20150001766A (en) 2012-04-12 2012-09-04 Method of manufacturing light emitting device
KR1020167036063A KR20160150657A (en) 2012-04-12 2012-09-04 Method of manufacturing light emitting device
CN201280071700.9A CN104170101B (en) 2012-04-12 2012-09-04 The method for manufacturing light-emitting device
JP2015504540A JP2015519728A (en) 2012-04-12 2012-09-04 Method for manufacturing a light emitting device

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261623488P 2012-04-12 2012-04-12
US61/623,488 2012-04-12

Publications (1)

Publication Number Publication Date
WO2013154602A1 true WO2013154602A1 (en) 2013-10-17

Family

ID=49328003

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2012/053706 WO2013154602A1 (en) 2012-04-12 2012-09-04 Method of manufacturing light emitting device

Country Status (7)

Country Link
US (1) US20150321387A1 (en)
EP (1) EP2837040A4 (en)
JP (2) JP2015519728A (en)
KR (2) KR20150001766A (en)
CN (1) CN104170101B (en)
SG (2) SG10201608345RA (en)
WO (1) WO2013154602A1 (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3300127A4 (en) * 2015-08-18 2018-04-25 Jiangsu Cherrity Optronics Co., Ltd Process method using thermoplastic resin photoconverter to bond-package led by rolling
WO2021030316A1 (en) * 2019-08-13 2021-02-18 Dow Silicones Corporation Method for making elastomeric articles
US11139419B2 (en) 2017-09-08 2021-10-05 Dupont Toray Specialty Materials Kabushiki Kaisha Method for producing sealed optical semiconductor device
US11257992B2 (en) 2017-09-08 2022-02-22 Dupont Toray Specialty Materials Kabushiki Kaisha Method for producing sealed optical semiconductor device

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012212963B4 (en) * 2012-07-24 2022-09-15 OSRAM Opto Semiconductors Gesellschaft mit beschränkter Haftung Process for producing an optoelectronic semiconductor component
CN106469768B (en) * 2015-08-18 2018-02-02 江苏诚睿达光电有限公司 A kind of special-shaped organic siliconresin light conversion body fitting encapsulation LED change system
KR101989042B1 (en) * 2015-08-18 2019-06-13 장쑤 체리티 옵트로닉스 컴퍼니, 리미티드 Equipment system for bonding and packaging LEDs with a thermoplastic resin photoconductor based on a rolling method
US10158051B2 (en) * 2015-08-18 2018-12-18 Jiangsu Cherity Optronics Co., Ltd. Process method for refining photoconverter to bond-package LED and refinement equipment system
CN106469767B (en) * 2015-08-18 2017-12-01 江苏诚睿达光电有限公司 A kind of change system of the organic siliconresin light conversion body fitting encapsulation LED based on series connection rolling
CN106469780B (en) * 2015-08-18 2018-02-13 江苏诚睿达光电有限公司 A kind of process of the organic siliconresin light conversion body fitting encapsulation LED based on series connection rolling
CN106469778B (en) * 2015-08-18 2017-12-22 江苏诚睿达光电有限公司 A kind of special-shaped organic siliconresin light conversion body fitting encapsulation LED process
WO2018008562A1 (en) * 2016-07-04 2018-01-11 旭硝子株式会社 Ethylene-tetrafluoroethylene copolymer film and method for producing same
CN114953652A (en) 2017-12-15 2022-08-30 西部制药服务有限公司 Smooth film laminated elastomeric articles

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20070034527A (en) * 2004-05-27 2007-03-28 미쓰비시 쥬시 가부시끼가이샤 Release Laminated Film
KR100790741B1 (en) * 2006-09-07 2008-01-02 삼성전기주식회사 Method for producing lens of light emitting device
WO2010117076A2 (en) 2009-04-10 2010-10-14 Dow Corning Toray Co., Ltd. Optical device and method of producing the same
WO2011037034A1 (en) * 2009-09-24 2011-03-31 旭硝子株式会社 Mold release film, and method for manufacturing light emitting diode
US20110108874A1 (en) * 2009-11-05 2011-05-12 Luminit, Llc Method to Provide Microstructure for Encapsulated Hgh-Brightness LED Chips

Family Cites Families (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001310336A (en) * 2000-04-28 2001-11-06 Asahi Glass Co Ltd Releasing film for molding resin mold
US20030071016A1 (en) * 2001-10-11 2003-04-17 Wu-Sheng Shih Patterned structure reproduction using nonsticking mold
US7344902B2 (en) * 2004-11-15 2008-03-18 Philips Lumileds Lighting Company, Llc Overmolded lens over LED die
US7985357B2 (en) * 2005-07-12 2011-07-26 Towa Corporation Method of resin-sealing and molding an optical device
CN100456505C (en) * 2006-04-10 2009-01-28 中强光电股份有限公司 Luminescence module
CN101067663A (en) * 2007-06-15 2007-11-07 清华大学 Lens used for LED light source
JP5164615B2 (en) * 2008-03-07 2013-03-21 信越ポリマー株式会社 Release film production method
TW201016800A (en) * 2008-09-26 2010-05-01 Whitford Corp Blended fluoropolymer coatings for rigid substrates
JP5472997B2 (en) * 2010-03-24 2014-04-16 信越ポリマー株式会社 Release film
JP5165715B2 (en) * 2010-03-24 2013-03-21 信越ポリマー株式会社 Release film
JP5636725B2 (en) * 2010-04-26 2014-12-10 大日本印刷株式会社 Release film for molding and method for producing the same
JP5600036B2 (en) * 2010-06-30 2014-10-01 帝人デュポンフィルム株式会社 Adhesive release polyester film for in-mold transfer materials
BR112013001195B1 (en) * 2010-12-28 2021-03-02 Nichia Corporation light-emitting device and method for making the same

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20070034527A (en) * 2004-05-27 2007-03-28 미쓰비시 쥬시 가부시끼가이샤 Release Laminated Film
KR100790741B1 (en) * 2006-09-07 2008-01-02 삼성전기주식회사 Method for producing lens of light emitting device
US20080061458A1 (en) 2006-09-07 2008-03-13 Samsung Electro-Mechanics Co., Ltd Mold for forming lens of light emitting diode package and method of manufacturing light emitting diode package using the same
WO2010117076A2 (en) 2009-04-10 2010-10-14 Dow Corning Toray Co., Ltd. Optical device and method of producing the same
KR20120022902A (en) * 2009-04-10 2012-03-12 다우 코닝 도레이 캄파니 리미티드 Optical device and method of producing the same
WO2011037034A1 (en) * 2009-09-24 2011-03-31 旭硝子株式会社 Mold release film, and method for manufacturing light emitting diode
US20110108874A1 (en) * 2009-11-05 2011-05-12 Luminit, Llc Method to Provide Microstructure for Encapsulated Hgh-Brightness LED Chips

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP2837040A4

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3300127A4 (en) * 2015-08-18 2018-04-25 Jiangsu Cherrity Optronics Co., Ltd Process method using thermoplastic resin photoconverter to bond-package led by rolling
US11139419B2 (en) 2017-09-08 2021-10-05 Dupont Toray Specialty Materials Kabushiki Kaisha Method for producing sealed optical semiconductor device
US11257992B2 (en) 2017-09-08 2022-02-22 Dupont Toray Specialty Materials Kabushiki Kaisha Method for producing sealed optical semiconductor device
WO2021030316A1 (en) * 2019-08-13 2021-02-18 Dow Silicones Corporation Method for making elastomeric articles
CN114206573A (en) * 2019-08-13 2022-03-18 美国陶氏有机硅公司 Method of making an elastomeric article

Also Published As

Publication number Publication date
SG10201608345RA (en) 2016-11-29
KR20150001766A (en) 2015-01-06
EP2837040A1 (en) 2015-02-18
JP2016201546A (en) 2016-12-01
JP2015519728A (en) 2015-07-09
CN104170101A (en) 2014-11-26
CN104170101B (en) 2018-02-09
EP2837040A4 (en) 2015-10-14
SG11201405896TA (en) 2014-11-27
US20150321387A1 (en) 2015-11-12
KR20160150657A (en) 2016-12-30

Similar Documents

Publication Publication Date Title
US20150321387A1 (en) Method of manufacturing light emitting device
CN105705307B (en) The manufacturing method of mold release film and semiconductor package body
US9061450B2 (en) Methods of forming packaged semiconductor light emitting devices having front contacts by compression molding
US7709853B2 (en) Packaged semiconductor light emitting devices having multiple optical elements
CN106104776B (en) The manufacturing method of mold release film, its manufacturing method and semiconductor package body
JP5106813B2 (en) Color conversion type light emitting diode
CN107000268B (en) The manufacturing method of mold release film and semiconductor package body
CN105705308B (en) The manufacture method of mold release film and semiconductor package body
JP2994219B2 (en) Method for manufacturing semiconductor device
US20110031516A1 (en) Led with silicone layer and laminated remote phosphor layer
US20170301832A1 (en) Glueless light emitting device with phosphor converter
WO2007080742A1 (en) Method of photoelement resin sealing/molding
WO2012023119A1 (en) Lamination process for leds
EP3300126B1 (en) Process method for refining photoconverter to bond-package led and refinement equipment system
JP5428122B2 (en) Resin molded product and molding method thereof, and light emitting device and manufacturing method thereof
JP2009200172A (en) Manufacturing method of optical semiconductor device, and manufacturing device of optical semiconductor device
CN111668114A (en) Semiconductor packaging method
JP2010263154A (en) Sheet for photosemiconductor encapsulation
TW201507214A (en) Light emitting diode and method of manufacturing the same
TW201511337A (en) Packaging method of light emitting diode and structure thereof

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 12874175

Country of ref document: EP

Kind code of ref document: A1

ENP Entry into the national phase

Ref document number: 2015504540

Country of ref document: JP

Kind code of ref document: A

NENP Non-entry into the national phase

Ref country code: DE

ENP Entry into the national phase

Ref document number: 20147029853

Country of ref document: KR

Kind code of ref document: A

WWE Wipo information: entry into national phase

Ref document number: 2012874175

Country of ref document: EP

WWE Wipo information: entry into national phase

Ref document number: 14394392

Country of ref document: US