Abstract
Thermoset materials offer a multitude of advantageous properties in terms of shrinkage and warpage as well as mechanical, thermal and chemical stability compared to thermoplastic materials. Thanks to these properties, thermosets are commonly used to encapsulate electronic components on a 2nd-level packaging prior to assembly by reflow soldering on printed circuits boards or other substrates. Based on the characteristics of thermosets to develop a distinct skin effect due to segregation during the molding process, the surface properties of injection molded thermoset components resemble optical characteristics. Within this study, molding parameters for thermoset components are analyzed in order to optimize the surface quality of injection molded thermoset components. Perspectively, in combination with a reflective coating by e.g., physical vapor deposition, such elements with micro-integrated reflective optical features can be used as optoelectronic components, which can be processed at medium-ranged temperatures up to 230 °C. The obtained results indicate the general feasibility since Ra values of 60 nm and below can be achieved. The main influencing parameters on surface quality were identified as the composition of filler materials and tool temperature.
Highlights
Micro-optical systems are essential in everyday life and industrial applications
design of experiment (DoE), which is shown in Appendix A, Table A1
The optimization of the surface quality towards reflective optical elements made by thermoset injection molding showed promising results
Summary
Micro-optical systems are essential in everyday life and industrial applications. This includes applications such as mobile phone cameras, driving assistance systems, light barriers, endoscopes, optical data storage, motion controllers, inspection systems, illumination units and many more [1,2,3,4,5,6].Optical components are omnipresent, very unobtrusive due to rapid advances in miniaturization and micro integration, making them non-observable for the user in most cases.behind these applications is a very versatile market for optical technologies, which is currently developing at an impressive speed of 6–8% p.a. [1,7]. Micro-optical systems are essential in everyday life and industrial applications. This includes applications such as mobile phone cameras, driving assistance systems, light barriers, endoscopes, optical data storage, motion controllers, inspection systems, illumination units and many more [1,2,3,4,5,6]. Very unobtrusive due to rapid advances in miniaturization and micro integration, making them non-observable for the user in most cases. Behind these applications is a very versatile market for optical technologies, which is currently developing at an impressive speed of 6–8% p.a. Costs can be reduced compared to glass components due to the
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