Method for making filled epoxy resin compositions

Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article

Reexamination Certificate

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C257S787000, C257S789000, C257S793000, C264S272130, C264S272170, C428S413000, C438S127000, C523S427000, C523S440000, C523S443000, C523S444000, C523S445000, C525S523000, C525S524000, C525S525000, C525S526000

Reexamination Certificate

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07381359

ABSTRACT:
An encapsulant is described for an optoelectronic device or optical component, which provides a coefficient of thermal expansion of less than 50 ppm/° C., with a variation of less than ±30%, and further provides an optical transmittance of at least 20% at a wavelength in the range of 400 to 900 nm, at an encapsulant thickness of about 1 mm. The encapsulant includes a filler consisting essentially of glass particles having diameters smaller than 500 μm, being essentially free of titania and lead oxide, and having a refractive index in the range of 1.48 to 1.60, with a variance of less than about 0.001. A method for making the encapsulant also is described, the method including steps of (1) processing the glass to form particles having diameters between 1 and 500 μm, (2) preparing an epoxy resin composition having at a cured stage a refractive index close to that of the glass filler particles, (3) mixing the epoxy resin composition with the filler particles to form a filled epoxy resin composition, (4) encapsulating an optoelectronic device with the filled epoxy resin composition, and (5) curing the filled epoxy resin composition.

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Machine translation of JP 2002-080698, provided by the JPO website (2002).
Machine translation of JP 06-065473, provided by the JPO website (1994).
Dunlap, P.N., et al., “Design of Particulate Composites for Optical Applications,”Polymer Composites, Feb. 1991, vol. 12, No. 1, pp. 39-47.
Nuganuma, T., et al., “Oprothermal properties of glass particle dispersed epoxy matrix composite,” Journal of Materials Science Letters, 1999, pp. 1587-1589.

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