Curable Composition Resolving Adhesion and Light Transmittance Trade-offs
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Solution Overview
Problem
Current encapsulants for photonic elements, such as epoxy resin and ethylene vinyl acetate, face issues with low light transmittance, interlayer peeling, moisture penetration, and UV radiation resistance, leading to degraded efficiency and reliability in LED and photoelectric conversion modules.
Innovation Solution
A curable composition comprising specific organopolysiloxanes and inorganic particles, which undergo a hydrosilylation reaction to form a partially cross-linked structure, enhancing light transmittance, crack resistance, and thermal shock resistance, while preventing precipitation of additives like fluorescent materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy resin is used as encapsulant, then adhesive properties and dynamic durability are improved, but light transmittance in blue to UV wavelength ranges deteriorates
Solution Approach 1:
The invention uses a composite material system consisting of organopolysiloxane base resin combined with specific inorganic particles (silica, alumina, or titania) with controlled refractive indices. This composite approach allows achieving both high light transmittance (90% or more in blue wavelength range) and adequate adhesive properties, resolving the contradiction between epoxy resin's high adhesion but poor light transmittance.
2Strength
If epoxy resin is used as encapsulant, then adhesive properties are improved, but light resistance deteriorates
Solution Approach 1:
The organopolysiloxane base resin combined with inorganic particles creates a composite encapsulant with superior light resistance while maintaining adhesive properties. The siloxane backbone provides UV stability and the inorganic particle reinforcement enhances overall durability, resolving the contradiction between adhesion and light resistance.
3Ease of manufacture
If EVA material is used as encapsulant, then ease of manufacture is improved, but adhesive properties deteriorate causing interlayer peeling
Solution Approach 1:
The invention changes the chemical composition parameters by using organopolysiloxane base resin with specific molecular weight ranges (1,000 to 50,000) and controlled viscosity (100 to 10,000 cP), combined with inorganic particles. This parameter optimization provides both ease of manufacture through proper flow characteristics and superior adhesive strength, preventing interlayer peeling while maintaining manufacturing simplicity.
4Ease of manufacture
If EVA material is used as encapsulant, then ease of manufacture is improved, but UV radiation resistance deteriorates causing discoloration
Solution Approach 1:
The organopolysiloxane base resin combined with inorganic particles (silica, alumina, or titania) creates a composite encapsulant with excellent UV radiation resistance that prevents discoloration. The siloxane structure inherently resists UV degradation while the inorganic particles provide additional stability, maintaining both ease of manufacture and superior UV resistance.
5Reliability
If inorganic particles are added to encapsulant, then heat resistance and crack resistance are improved, but light transmittance may deteriorate
Solution Approach 1:
The invention applies local quality control by carefully selecting inorganic particles with specific refractive indices (1.40-1.60 for silica, 1.55-1.75 for alumina, 1.80-2.20 for titania) that match the encapsulant matrix. This selective matching minimizes light scattering at particle interfaces, allowing the inclusion of inorganic particles for heat and crack resistance while maintaining high light transmittance (90% or more in blue wavelength range).
Solution Approach 2:
The invention optimizes particle parameters including refractive index matching, particle size distribution (0.1 to 10 μm average diameter), and content ratio (10 to 90 wt% of total inorganic particles). These parameter changes ensure that inorganic particles provide heat resistance and crack resistance without significantly deteriorating light transmittance properties.
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
The composition achieves excellent processability, workability, light extraction efficiency, and thermal shock resistance, ensuring superior reliability and preventing surface stickiness and opacity, even under severe conditions.
Implementation Method 1
A curable composition including components which can be cured by a hydrosilylation reaction such as a reaction of a hydrogen atom with an unsaturated aliphatic bond of an alkenyl group
Data Source
AI summary
A curable composition and use thereof are provided. The composition can be useful in exhibiting excellent processability and workability, and providing a cured product which exhibits superior light extraction efficiency, crack resistance, hardness, thermal shock resistance, and adhesive properties, has superior reliability under severe conditions for a long period of time and prevents opacity and stickiness onto a surface thereof when cured. Also, the curable composition capable of preventing precipitation of an additive such as a fluorescent material or a photoconversion material and being formed into a cured product having excellent transparency even when the additive is added to the curable composition can be provided.