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US20110311788A1 - Silphenylene-containing photocurable composition, pattern formation method using same, and optical semiconductor element obtained using the method - Google Patents

Silphenylene-containing photocurable composition, pattern formation method using same, and optical semiconductor element obtained using the method Download PDF

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Publication number
US20110311788A1
US20110311788A1 US13/163,174 US201113163174A US2011311788A1 US 20110311788 A1 US20110311788 A1 US 20110311788A1 US 201113163174 A US201113163174 A US 201113163174A US 2011311788 A1 US2011311788 A1 US 2011311788A1
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photocurable composition
silphenylene
derivatives
component
group
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Inventor
Shohei Tagami
Takato SAKURAI
Hideto Kato
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Shin Etsu Chemical Co Ltd
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Shin Etsu Chemical Co Ltd
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Assigned to SHIN-ETSU CHEMICAL CO., LTD. reassignment SHIN-ETSU CHEMICAL CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KATO, HIDETO, SAKURAI, TAKATO, TAGAMI, SHOHEI
Publication of US20110311788A1 publication Critical patent/US20110311788A1/en
Priority to US14/019,910 priority Critical patent/US8715905B2/en
Abandoned legal-status Critical Current

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    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/004—Photosensitive materials
    • G03F7/075—Silicon-containing compounds
    • G03F7/0754—Non-macromolecular compounds containing silicon-to-silicon bonds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00—Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/20—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the epoxy compounds used
    • C08G59/22—Di-epoxy compounds
    • C08G59/30—Di-epoxy compounds containing atoms other than carbon, hydrogen, oxygen and nitrogen
    • C08G59/306—Di-epoxy compounds containing atoms other than carbon, hydrogen, oxygen and nitrogen containing silicon
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/0005—Production of optical devices or components in so far as characterised by the lithographic processes or materials used therefor
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
    • G03F7/004—Photosensitive materials
    • G03F7/075—Silicon-containing compounds
    • G03F7/0755—Non-macromolecular compounds containing Si-O, Si-C or Si-N bonds
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
    • H01L21/027—Making masks on semiconductor bodies for further photolithographic processing not provided for in group H01L21/18 or H01L21/34
    • H01L21/0271—Making masks on semiconductor bodies for further photolithographic processing not provided for in group H01L21/18 or H01L21/34 comprising organic layers
    • H01L21/0273—Making masks on semiconductor bodies for further photolithographic processing not provided for in group H01L21/18 or H01L21/34 comprising organic layers characterised by the treatment of photoresist layers
    • H01L21/0274—Photolithographic processes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2312/00—Crosslinking
    • C08L2312/06—Crosslinking by radiation
    • 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.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Definitions

  • the present invention relates to a silphenylene-containing photocurable composition, a pattern formation method that uses the composition, and an optical semiconductor element obtained using the method.
  • the invention relates particularly to a silphenylene-containing photocurable composition which, due to its superior properties of transparency, light resistance and heat resistance, is useful in optical devices typified by light-emitting elements such as light-emitting diodes (LED), light-receiving elements such as photodiodes, optical sensors and CMOS image sensors, and optical transmission devices such as optical waveguides, as well as a pattern formation method that uses the silphenylene-containing photocurable composition, and an optical semiconductor element obtained using the method.
  • light-emitting elements such as light-emitting diodes (LED), light-receiving elements such as photodiodes, optical sensors and CMOS image sensors, and optical transmission devices
  • optical waveguides such as optical waveguides
  • the present invention has been developed in light of the above circumstances, and has an object of providing a silphenylene-containing photocurable composition that is capable of very fine pattern formation across a broad range of wavelengths, and following pattern formation, yields a film that exhibits a high degree of transparency and superior light resistance, as well as providing a pattern formation method that uses the silphenylene-containing photocurable composition, and an optical semiconductor element that is obtained using the pattern formation method.
  • a photocurable composition described below comprising a specific alicyclic epoxy-modified silphenylene compound, could be exposed with light across a broad range of wavelengths, enabling ready formation of a cured product with no oxygen inhibition.
  • the pattern formation method described below enabled the formation of very fine patterns, and that optical semiconductor elements produced using the above-mentioned photocurable composition and pattern formation method exhibited excellent transparency and light resistance, and they were therefore able to complete the present invention.
  • a first aspect of the present invention provides a silphenylene-containing photocurable composition comprising:
  • (C) a photoacid generator that generates acid upon irradiation with light having a wavelength of 240 to 500 nm.
  • the photocurable composition may further comprise:
  • each R independently represents a hydrogen atom or a monovalent organic group, at least one R comprises an epoxy group
  • a, b and c each represents an integer of 0 or greater
  • d represents an integer of 0 or greater
  • e represents an integer of 1 or greater
  • W X and Y each represents a divalent organic group
  • f, g and h each independently represents 0 or 1, provided that when a and c are 0, b is 1 and g is 0, the R groups do not both represent epoxy group-containing organic groups represented by the formula below).
  • a second aspect of the present invention provides a cured film obtained by curing the above photocurable composition.
  • a third aspect of the present invention provides a pattern formation method comprising:
  • a fourth aspect of the present invention provides an optical semiconductor element obtained by performing pattern formation using the method described above.
  • a fifth aspect of the present invention provides use of the above-mentioned photocurable composition for pattern formation.
  • the photocurable composition of the present invention comprising a specific alicyclic epoxy-modified silphenylene compound
  • exposure can be performed with light across a broad range of wavelengths, and thin films can be formed readily with no oxygen inhibition.
  • very fine patterns of 10 ⁇ m or less can be formed, and the cured films obtained from the composition exhibit excellent transparency, light resistance and heat resistance, meaning they can be used favorably for protecting and encapsulating optical devices and the like.
  • FIG. 1 is a graph illustrating the results of investigating the change over time in the light transmission of a sample of Example 5 composed of a cured film sandwiched between glass wafers, wherein the initial transmission was deemed to be 100%.
  • the component (A) is a silphenylene having both terminals modified with alicyclic epoxy groups, represented by formula (1) shown above.
  • the component (A) can be produced, for example as described below in Synthesis Example 1, by subjecting a 2/1 molar ratio of 1,2-epoxy-4-vinylcyclohexane and 1,4-bis(dimethylsilyl)benzene to a hydrosilylation reaction using normal methods.
  • the component (B) is an epoxy group-containing organosilicon compound represented by general formula (2) shown above.
  • the component (B) is an optional component, and may be either included or not included in the photocurable composition of the present invention.
  • the component (B) may be either a single compound or a combination of two or more different compounds.
  • each R independently represents a hydrogen atom or a monovalent organic group, and at least one R group, and preferably 20 mol % or more of the R groups, comprise an epoxy group. If the general formula (2) does not include a single R group that comprises an epoxy group, then cross-linking between the component (A) and the component (B) does not proceed.
  • the R groups may be the same or different.
  • R examples include a hydrogen atom, monovalent hydrocarbon groups of 1 to 8 carbon atoms, and epoxy group-containing organic groups represented by the formulas shown below.
  • the monovalent hydrocarbon groups of 1 to 8 carbon atoms for R include alkyl groups such as a methyl group, ethyl group, propyl group, butyl group, pentyl group or hexyl group, cycloalkyl groups such as a cyclopentyl group or cyclohexyl group, aryl groups such as a phenyl group, and aralkyl groups such as a benzyl group or phenethyl group. From the viewpoint of ease of availability of the raw material, a methyl group, ethyl group or phenyl group is preferred. Appropriate selection of R from the various possibilities mentioned above makes it easier to achieve a combination of favorable transparency and superior pattern formability.
  • a, b and c each represents an integer of 0 or greater. Although there are no particular limitations on a, provided it is an integer of 0 or greater, an integer of 0 to 10 is typical. Further, although there are no particular limitations on b, provided it is an integer of 0 or greater, an integer of 0 to 10 is typical. Similarly, although there are no particular limitations on c, provided it is an integer of 0 or greater, an integer of 0 to 10 is typical.
  • the repeating units to which a, b and c are appended need not necessarily be linked continuously, and need not necessarily be linked in the sequence shown in the above formula, meaning the repeating units may be linked in a random order. In those cases where a, b or c is 2 or greater, indicating a plurality of the corresponding repeating unit, the plurality of repeating units may be the same or different.
  • d represents an integer of 0 or greater
  • e represents an integer of 1 or greater.
  • d represents an integer of 0 or greater
  • e represents an integer of 1 or greater.
  • W, X and Y represent divalent organic groups. Each of W, X and Y may represent one type of group or a plurality of different groups. W, X and Y preferably represent divalent organic groups represented by general formula (3) shown below:
  • the divalent organic groups represented by general formula (3) above are produced, for example, by using the corresponding linear dimethylsiloxane having vinyl groups at both terminals as a raw material.
  • i represents an integer of 0 to 10, but is typically an integer of 0 or 1.
  • f, g and h each represents 0 or 1.
  • f is preferably 0, but when the same unit is positioned at a location other than the right terminal in general formula (2), f is preferably 1.
  • g is preferably 0, but when the same unit is positioned at a location other than the right terminal in general formula (2), g is preferably 1.
  • h is preferably 0, but when the same unit is positioned at a location other than the right terminal in general formula (2), h is preferably 1.
  • component (B) examples include the epoxy group-containing organosilicon compounds represented by general formula (2′) shown below:
  • a′, b′ and c′ each represents an integer of 0 or greater, R, d, e, W, X and Y are the same as defined above, and Z represents a divalent organic group represented by one of the formulas shown below:
  • the R groups do not both represent epoxy group-containing organic groups represented by the formula below).
  • the divalent organic group represented by Z is produced, for example, by using the equivalent SiH group-containing organosilicon compound that includes an additional two hydrogen atoms on the divalent organic group (namely, the compound that includes silicon atom-bonded hydrogen atoms at both terminals) as a raw material.
  • component (B) includes the structures shown below.
  • Adding the component (B) facilitates regulation of the viscosity of the resulting composition, making it easier to achieve the required film thickness and effectively improving the flexibility of the resulting cured product.
  • the amount added of the component (B) is preferably within a range from 0.5 to 900 parts by mass, and more preferably from 10 to 200 parts by mass, per 100 parts by mass of the component (A). Provided the amount of the component (B) satisfies this range from 0.5 to 900 parts by mass, the effect of including the component (B) can be achieved satisfactorily, while maintaining good compatibility between the epoxy group-containing organosilicon compound of the component (B) and the photoacid generator of the component (C).
  • the component (B) is not necessarily limited to a single compound, and a plurality of different compounds may also be used in combination.
  • the component (B) can be produced, for example, by mixing together appropriate amounts of vinyl group-containing compounds and SiH group-containing organosilicon compounds corresponding with each of the portions of the component (B), and then performing a hydrosilylation reaction in accordance with normal methods.
  • the component (C) is a photoacid generator that generates acid upon irradiation with light having a wavelength of 240 to 500 nm, and is used as a curing catalyst.
  • this type of photoacid generator include onium salts, diazomethane derivatives, glyoxime derivatives, ⁇ -ketosulfone derivatives, disulfone derivatives, nitrobenzyl sulfonate derivatives, sulfonate ester derivatives, imidoyl sulfonate derivatives, oxime sulfonate derivatives, iminosulfonate derivatives and triazine derivatives.
  • Examples of the above-mentioned onium salts include compounds represented by general formula (4) shown below.
  • R 1 represents a linear, branched or cyclic alkyl group of 1 to 12 carbon atoms, an aryl group of 6 to 12 carbon atoms or an aralkyl group of 7 to 12 carbon atoms, which may have a substituent
  • M + represents an iodonium or sulfonium ion
  • K′′ represents a non-nucleophilic counter ion
  • h represents 2 or 3.
  • alkyl group for R 1 examples include a methyl group, ethyl group, propyl group, butyl group, cyclohexyl group, 2-oxocyclohexyl group, norbornyl group or adamantyl group.
  • Examples of the aryl group for R 1 include alkoxyphenyl groups such as an o-, m- or p-methoxyphenyl group, ethoxyphenyl group, or m- or p-tert-butoxyphenyl group, and alkylphenyl groups such as a 2-, 3- or 4-methylphenyl group, ethylphenyl group, 4-tert-butylphenyl group, 4-butylphenyl group or dimethylphenyl group.
  • examples of the aralkyl group for R 1 include a benzyl group or phenethyl group.
  • non-nucleophilic counter-ion represented by K ⁇ examples include halide ions such as a chloride ion or bromide ion, fluoroalkylsulfonate ions such as triflate, 1,1,1-trifluoroethanesulfonate and nonafluorobutanesulfonate ions, arylsulfonate ions such as tosylate, benzenesulfonate, 4-fluorobenzenesulfonate and 1,2,3,4,5-pentafluorobenzenesulfonate ions, alkylsulfonate ions such as mesylate and butanesulfonate ions, as well as a hexafluorophosphate ion and fluorinated alkylfluorophosphate ions.
  • halide ions such as a chloride ion or bromide ion
  • fluoroalkylsulfonate ions such as tri
  • Examples of the above-mentioned diazomethane derivatives include compounds represented by general formula (5) shown below.
  • R 2 groups may be the same or different, and each represents a linear, branched or cyclic alkyl group or halogenated alkyl group of 1 to 12 carbon atoms, an aryl group or halogenated aryl group of 6 to 12 carbon atoms, or an aralkyl group of 7 to 12 carbon atoms.
  • alkyl group for R 2 examples include a methyl group, ethyl group, propyl group, butyl group, amyl group, cyclopentyl group, cyclohexyl group, norbornyl group or adamantyl group.
  • halogenated alkyl group for R 2 examples include a trifluoromethyl group, 1,1,1-trifluoroethyl group, 1,1,1-trichloroethyl group or nonafluorobutyl group.
  • Examples of the aryl group for R 2 include a phenyl group, alkoxyphenyl groups such as an o-, m- or p-methoxyphenyl group, ethoxyphenyl group, or m- or p-tert-butoxyphenyl group, and alkylphenyl groups such as a 2-, 3- or 4-methylphenyl group, ethylphenyl group, 4-tert-butylphenyl group, 4-butylphenyl group or dimethylphenyl group.
  • Examples of the halogenated aryl group for R 2 include a fluorophenyl group, chlorophenyl group or 1,2,3,4,5-pentafluorophenyl group.
  • Examples of the aralkyl group for R 2 include a benzyl group or phenethyl group.
  • Examples of the above-mentioned glyoxime derivatives include compounds represented by general formula (6) shown below.
  • R 3 groups and the R 4 groups may be the same or different, and each represents a linear, branched or cyclic alkyl group or halogenated alkyl group of 1 to 12 carbon atoms, an aryl group or halogenated aryl group of 6 to 12 carbon atoms, or an aralkyl group of 7 to 12 carbon atoms.
  • the R 4 groups may be bonded together to form a cyclic structure, and in those cases where such a cyclic structure is formed, R 4 represents a linear or branched alkylene group of 1 to 6 carbon atoms.
  • Examples of the alkyl group, halogenated alkyl group, aryl group, halogenated aryl group or aralkyl group for R 3 and R 4 include the same groups as those exemplified above for R 2 .
  • Examples of the alkylene group for R 4 include a methylene group, ethylene group, propylene group, butylene group or hexylene group.
  • photoacid generator on the component (C) include:
  • onium salts such as diphenyliodonium trifluoromethanesulfonate, (p-tert-butoxyphenyl)phenyliodonium trifluoromethanesulfonate, diphenyliodonium p-toluenesulfonate, (p-tert-butoxyphenyl)phenyliodonium p-toluenesulfonate, triphenylsulfonium trifluoromethanesulfonate, (p-tert-butoxyphenyl)diphenylsulfonium trifluoromethanesulfonate, bis(p-tert-butoxyphenyl)phenylsulfonium trifluoromethanesulfonate, tris(p-tert-butoxyphenyl)sulfonium trifluoromethanesulfonate, triphenylsulfonium p-toluenesulfonate, (
  • diazomethane derivatives such as bis(benzenesulfonyl)diazomethane, bis(p-toluenesulfonyl)diazomethane, bis(xylenesulfonyl)diazomethane, bis(cyclohexylsulfonyl)diazomethane, bis(cyclopentylsulfonyl)diazomethane, bis(n-butylsulfonyl)diazomethane, bis(isobutylsulfonyl)diazomethane, bis(sec-butylsulfonyl)diazomethane, bis(n-propylsulfonyl)diazomethane, bis(isopropylsulfonyl)diazomethane, bis(tert-butylsulfonyl)diazomethane, bis(n-amylsulfonyl)
  • glyoxime derivatives such as bis-o-(p-toluenesulfonyl)- ⁇ -dimethylglyoxime, bis-o-(p-toluenesulfonyl)- ⁇ -diphenylglyoxime, bis-o-(p-toluenesulfonyl)- ⁇ -dicyclohexylglyoxime, bis-o-(p-toluenesulfonyl)-2,3-pentanedioneglyoxime, bis-o-(p-toluenesulfonyl)-2-methyl-3,4-pentanedioneglyoxime, bis-o-(n-butanesulfonyl)- ⁇ -dimethylglyoxime, bis-o-(n-butanesulfonyl)- ⁇ -diphenylglyoxime, bis-o-(n-butanesulfonyl)- ⁇ -dicyclo
  • oxime sulfonate derivatives such as ⁇ -(benzenesulfoniumoxyimino)-4-methylphenylacetonitrile
  • ⁇ -ketosulfone derivatives such as 2-cyclohexylcarbonyl-2-(p-toluenesulfonyl)propane and 2-isopropylcarbonyl-2-(p-toluenesulfonyl)propane;
  • disulfone derivatives such as diphenyl disulfone and dicyclohexyl disulfone
  • nitrobenzyl sulfonate derivatives such as 2,6-dinitrobenzyl p-toluenesulfonate and 2,4-dinitrobenzyl p-toluenesulfonate;
  • sulfonate ester derivatives such as 1,2,3-tris(methanesulfonyloxy)benzene, 1,2,3-tris(trifluoromethanesulfonyloxy)benzene, and 1,2,3-tris(p-toluenesulfonyloxy)benzene; and imidoyl sulfonate derivatives such as phthalimidoyl triflate, phthalimidoyl tosylate, 5-norbornene-2,3-dicarboxyImidoyl triflate, 5-norbornene-2,3-dicarboxyImidoyl tosylate, 5-norbornene-2,3-dicarboxyImidoyl n-butylsulfonate, and n-trifluoromethylsulfonyloxynaphthylimide.
  • imidoyl sulfonate derivatives such as phthalimidoyl triflat
  • iminosulfonate derivatives such as (5-(4-methylphenyl)sulfonyloxyimino-5H-thiophen-2-ylidene)-(2-methylphenyl)acetonitrile and (5-(4-(4-methylphenylsulfonyloxy)phenylsulfonyloxyimino)-5H-thiophen-2-ylidene)-(2-methylphenyl)acetonitrile.
  • an onium salt or a sulfonium salt-based derivative is particularly desirable.
  • the component (C) a single compound may be used alone, or two or more different compounds may be mixed.
  • the amount added of the component (C) is preferably within a range from 0.05 to 20 parts by mass, more preferably from 0.2 to 5 parts by mass, and still more preferably 0.5 to 2 parts by mass, per 100 parts by mass of the component (A) or per 100 parts by mass of the combination of the component (A) and the component (B). Provided the amount of the component (C) satisfies this range from 0.05 to 20 parts by mass, satisfactory photocuring properties can be readily achieved, and the problem wherein the acid generator itself absorbs light, causing a deterioration in the curing properties within thick films, can be effectively prevented.
  • the photocurable composition of the present invention may also contain an organic solvent as a component (D) according to need.
  • the organic solvent is preferably a solvent that is capable of dissolving the silphenylene having both terminals modified with alicyclic epoxy groups of the component (A), the epoxy group-containing organosilicon compound of the component (B), and the photoacid generator of the component (C) and the like.
  • the component (D) may be either a single solvent or a combination of two or more different solvents.
  • Examples of the organic solvent of the component (D) include ketones such as cyclohexanone, cyclopentanone and methyl 2-n-amyl ketone, alcohols such as 3-methoxybutanol, 3-methyl-3-methoxybutanol, 1-methoxy-2-propanol and 1-ethoxy-2-propanol, ethers such as propylene glycol monomethyl ether, ethylene glycol monomethyl ether, propylene glycol monoethyl ether, ethylene glycol monoethyl ether, propylene glycol dimethyl ether and diethylene glycol dimethyl ether, esters such as propylene glycol monomethyl ether acetate, propylene glycol monoethyl ether acetate, ethyl lactate, ethyl pyruvate, butyl acetate, methyl 3-methoxypropionate, ethyl 3-ethoxypropionate, tert-butyl acetate, tert
  • solvents that exhibit superior solubility of the photoacid generator including cyclohexanone, cyclopentanone, propylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, or a mixed solvent containing two or more of these solvents are particularly preferred.
  • the photocurable composition of the present invention may also include other added components.
  • these other added components include antioxidants such as hindered amines and hindered phenols. These compounds may be included in amounts that do not impair the transparency of the cured product.
  • the above-mentioned photocurable composition is first applied to a substrate.
  • the substrate include a silicon wafer, glass wafer or quartz wafer, or a plastic circuit board or ceramic circuit board.
  • preliminary heating may be performed if necessary to volatilize the solvent or the like. This preliminary heating is typically performed by heating at 40 to 140° C. for a period of approximately one minute to one hour. Subsequently, the film is exposed through a photomask with light having a wavelength of 240 to 500 nm, thereby curing the film.
  • the photomask may include a desired pattern cut therein.
  • the material of the photomask preferably blocks the above light having a wavelength of 240 to 500 nm, and a material such as chrome can be used favorably, although the present invention is not limited to such materials.
  • Examples of the above-mentioned light having a wavelength of 240 to 500 nm include lights of various wavelengths generated by appropriate radiation-generating devices, including ultraviolet light such as g-line and i-line radiation, and far ultraviolet light (248 nm).
  • the exposure dose is preferably within a range from 10 to 5,000 mJ/cm 2 .
  • a heating treatment may be performed following the exposure in order to improve the developing sensitivity. This post-exposure heating treatment is typically conducted at a temperature of 40 to 140° C. for a period of 0.5 to 10 minutes.
  • the pattern formation method is as described above, but in those cases where a pattern need not be formed, namely in those cases where a simple uniform film is to be formed, the method may be conducted in the same manner as the pattern formation method described above, with the exception of not using the above-mentioned photomask. Furthermore, if necessary, the resulting pattern may be heated in an oven or on a hotplate at 120 to 300° C. for a period of approximately 10 minutes to 10 hours in order to increase the cross-linking density and remove any residual volatile components (so-called post-curing).
  • an optical semiconductor element having superior transparency, light resistance and heat resistance can be obtained.
  • the cured film obtained from the photocurable composition in the manner described above exhibits excellent levels of transparency, light resistance and heat resistance, and an optical semiconductor element obtained by forming a fine pattern from this cured film can be used favorably in optical devices such as light-emitting elements, light-receiving elements and optical transmission devices.
  • a flask fitted with a stirrer and a thermometer was charged with 49.7 g (0.4 mols) of 1,2-epoxy-4-vinylcyclohexane, 500 g of toluene and 0.5 g of a 2% by mass ethanol solution of chloroplatinic acid, and with the flask contents undergoing constant stirring, the flask was heated using an oil bath until the internal temperature reached 70° C. Subsequently, 38.9 g (0.2 mols) of 1,4-bis(dimethylsilyl)benzene was added dropwise to the flask over a period of 20 minutes. Following completion of the dropwise addition, the reaction mixture was stirred for 3 hours at 90° C.
  • reaction liquid was subjected to a distillation treatment under heating and reduced pressure (50° C., 1 mmHg) using a rotary evaporator until no further distillate was produced, thus yielding 85 g of a silphenylene (A-1) having both terminals modified with alicyclic epoxy groups that represents the component (A).
  • a flask fitted with a stirrer and a thermometer was charged with 49.7 g (0.4 mols) of 1,2-epoxy-4-vinylcyclohexane, 500 g of toluene and 0.5 g of a 2% by mass ethanol solution of chloroplatinic acid, and with the flask contents undergoing constant stirring, the flask was heated using an oil bath until the internal temperature reached 70° C. Subsequently, 65.1 g (0.1 mols) of an organosiloxane having an average structure represented by formula (7) shown below was added dropwise to the flask over a period of 20 minutes. Following completion of the dropwise addition, the reaction mixture was stirred for 3 hours at 90° C.
  • reaction liquid was subjected to a distillation treatment under heating and reduced pressure (50° C., 1 mmHg) using a rotary evaporator until no further distillate was produced, thus yielding 110 g of an epoxy-modified siloxane compound (B-1) having an average structure represented by formula (8) shown below.
  • a flask fitted with a stirrer and a thermometer was charged with 27.3 g (0.22 mols) of 1,2-epoxy-4-vinylcyclohexane, 16.8 g (0.09 mols) of 1,3-divinyl-1,1,3,3-tetramethylpropanedisiloxane, 500 g of toluene and 0.5 g of a 2% by mass ethanol solution of chloroplatinic acid, and with the flask contents undergoing constant stirring, the flask was heated using an oil bath until the internal temperature reached 70° C.
  • a flask fitted with a stirrer and a thermometer was charged with 22.4 g (0.18 mols) of 1,2-epoxy-4-vinylcyclohexane, 16.8 g (0.09 mols) of 1,3-divinyl-1,1,3,3-tetramethylpropanedisiloxane, 500 g of toluene and 0.5 g of a 2% by mass ethanol solution of chloroplatinic acid, and with the flask contents undergoing constant stirring, the flask was heated using an oil bath until the internal temperature reached 70° C.
  • the composition of each example was coated onto one 6-inch silicon wafer that had been primed with hexamethyldisilazane and one 6-inch glass wafer to form a film of the thickness shown in Table 1 in each case.
  • the silicon wafer and the glass wafer were each placed on a hotplate and heated at 100° C. for 2 minutes.
  • the coated wafer substrate was dipped in propylene glycol monomethyl ether acetate for 3 minutes to develop the composition.
  • the narrowest line width resolved during the developing is listed in Table 1. Further, the film thickness following developing is also listed in Table 1.
  • the entire surface of the composition applied to the glass wafer was irradiated directly with light from a high-pressure mercury lamp, without using a quartz mask, using a Mask Aligner MA8 manufactured by SUSS MicroTec AG.
  • a post-exposure heat treatment was performed, and the composition was then developed by dipping in propylene glycol monomethyl ether acetate.
  • the film that was left following these operations was then heated in an oven for one hour at 180° C., yielding a cured film. This cured film was measured for light transmission of light having a wavelength of 405 nm. The results are shown in Table 2.
  • Example 2 The composition used in Example 2 was applied to a glass wafer, and subjected to total-surface exposure, post-exposure heating and developing operations in the same manner as described above for Example 2. Subsequently, with the wafer positioned on a hotplate at 140° C., another glass wafer was bonded to the coated surface. Following this operation, the bonded structure was heated in an oven at 180° C. for one hour, yielding a sample composed of a cured film sandwiched between two glass wafers.
  • Example 1 Example 2
  • Example 3 Example 4 Light transmission 99.9 99.7 99.1 99.2 (%, 405 nm)

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