Curable Composition for LED Encapsulation

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Solution Overview

Problem

Conventional epoxy resins used as LED encapsulants have low light transmittance and light resistance, particularly in the blue and UV regions, and are prone to surface stickiness and mechanical durability issues.

Innovation Solution

A curable composition comprising a polyorganosiloxane with specific compositional formulas and a silicon compound with a hydrogen atom, which undergoes hydrosilylation to form a crosslinked structure, enhancing light transmittance, mechanical strength, and adhesiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If epoxy resin is used as LED encapsulant, then adhesiveness and mechanical durability are improved, but light transmittance in blue/UV region and light resistance deteriorate

Engineering Contradiction:
Improvemechanical durabilityVSAvoidlight transmittance
Core Design Contradiction:
StrengthVSIllumination intensity

Solution Approach 1:

The patent employs a composite material system consisting of polyorganosiloxane base resin combined with specific inorganic fillers (silica, alumina, titania) and fluorescent materials. This composite structure achieves both high mechanical durability from the crosslinked siloxane network and excellent light transmittance in blue/UV regions through careful selection of filler materials with appropriate refractive indices and optical properties, thereby resolving the contradiction between mechanical strength and optical performance.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent utilizes parameter changes by controlling the molecular weight, hydroxyl value, and compositional ratios of polyorganosiloxane components, along with adjusting filler content and particle size distribution. These parameter optimizations enable the material to simultaneously achieve high adhesiveness, mechanical durability, and superior light transmittance in the blue/UV spectrum, overcoming the limitations of conventional epoxy resins.

Inventive Principle:
Principle #35Parameter changes

2Strength

If epoxy resin is used as LED encapsulant, then adhesiveness is improved, but light resistance deteriorates

Engineering Contradiction:
ImproveadhesivenessVSAvoidlight resistance
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent creates a composite material system where polyorganosiloxane base resin is combined with inorganic fillers (silica, alumina, titania) and fluorescent materials. The siloxane backbone provides inherent UV resistance and stability, while the inorganic fillers enhance both mechanical adhesion and optical stability under LED irradiation, achieving simultaneous improvement in adhesiveness and light resistance that epoxy resins cannot provide.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent optimizes parameters including hydroxyl value (5-50 mg KOH/g), molecular weight, and compositional ratios of polyorganosiloxane components. These parameter controls enable the material to achieve high adhesiveness through controlled crosslinking density while maintaining excellent light resistance and preventing yellowing under prolonged LED operation, thereby resolving the contradiction between adhesion and optical stability.

Inventive Principle:
Principle #35Parameter changes

3Ease of manufacture

If conventional encapsulant material is used, then manufacturing simplicity is maintained, but crack resistance and thermal resistance deteriorate

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidcrack resistance
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent utilizes parameter changes by controlling the molecular weight, hydroxyl value, and compositional ratios of polyorganosiloxane components. These parameter optimizations enable the material to simultaneously achieve high mechanical durability, crack resistance, and thermal stability while maintaining ease of manufacturing through standard encapsulation processes, thereby resolving the contradiction between manufacturing simplicity and enhanced reliability.

Inventive Principle:
Principle #35Parameter changes

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 curable composition exhibits excellent light extraction efficiency, crack resistance, hardness, thermal and shock resistance, and long-lasting durability without surface stickiness, making it suitable for encapsulating LEDs.

Implementation Method 1

components that can be cured by hydrosilylation, for example, a reaction between an aliphatic unsaturated bond and a hydrogen atom

Methodology Applied
Scientific EffectHydrosilylation: Chemical Bonding

Data Source

PatentEP2878634B1Curable composition
Publication Date: 2017.10.04 LG CHEM LTD
  • EP2878634B1 patent drawing
  • EP2878634B1 patent drawing
  • EP2878634B1 patent drawing

AI summary

Provided are a curable composition and its use. The curable composition has excellent processability, workability and adhesiveness, exhibits excellent light extraction efficiency, crack resistance, hardness, thermal and shock resistance and adhesiveness after curing, has long-lasting durability and reliability even under harsh conditions, and does not cause whitening or surface stickiness. The curable composition can be used as an encapsulant or adhesive material for an optical semiconductor such as an LED.