Concave Silicone Light-Transmissive Member for Stable Light Extraction
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Solution Overview
Problem
The existing imprint method for forming microscopic concave and convex patterns is limited to thermoplastic or ultraviolet-curable resins in an uncured state, restricting the materials that can be used for forming light-transmissive members and light emitting devices with improved light extraction efficiency.
Innovation Solution
A method involving a die with convex portions is pressed onto a cured silicone resin body in a heated state to form concave portions, followed by ultraviolet irradiation, allowing for the formation of light-transmissive members with concave and convex patterns on cured thermosetting resin bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the imprint method is used to form a microscopic concave and convex pattern, then the light extraction efficiency is improved, but the material selection is limited to thermoplastic or ultraviolet-curable resins in an uncured state
Solution Approach 1:
The patent changes the physical state parameter of the resin from uncured to cured, and uses heating to temporarily restore formability. This allows cured resin bodies to be imprinted with concave and convex patterns while maintaining shape stability at high temperatures, resolving the contradiction between material selection flexibility and thermal stability.
Solution Approach 2:
The resin body is cured in advance before the imprinting process. This preliminary curing action ensures shape stability while the heating step temporarily restores formability during imprinting. The sequence of preliminary curing followed by controlled heating and imprinting enables both material flexibility and thermal stability.
2Stability of the object's composition
If a cured resin body is used instead of an uncured resin, then the shape stability is improved, but the formability during imprinting deteriorates
Solution Approach 1:
The patent applies periodic heating to the cured resin body to temporarily restore formability during the imprinting process. The heating is applied only when needed for imprinting, allowing the resin to transition between cured (stable) and heated (formable) states periodically, thus resolving the contradiction between shape stability and formability.
Solution Approach 2:
The patent utilizes a phase transition-like effect where heating the cured resin body temporarily changes its physical state from rigid to formable. This controlled phase transition enables the resin to be imprinted while maintaining its cured state's shape stability, balancing formability and stability requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the formation of light-transmissive members with enhanced light extraction efficiency and stability, maintaining the shape of concave portions even at high temperatures, thus improving the performance of light emitting devices.
Implementation Method 1
pressing the die onto the principal surface of the resin body in a heated state to form a plurality of concave portions at the principal surface
Implementation Method 2
after the step (A), irradiating the principal surface of the resin body with ultraviolet rays
Data Source
AI summary
A light emitting device includes: a light emitting element having a top surface; and a light-transmissive member covering at least the top surface of the light emitting element, the light-transmissive member having a principal surface located above the top surface of the light emitting element. The principal surface of the light-transmissive member comprises a plurality of concave portions.