Curable Resin Composition for Photosemiconductor Apparatus
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Solution Overview
Problem
The challenge is to develop a curable resin composition for photosemiconductor apparatuses that maintains stable phosphor dispersion and color rendering properties throughout the manufacturing process without using fillers, as existing methods fail to prevent phosphor sedimentation and resulting fluctuations in light emission characteristics.
Innovation Solution
A curable resin composition comprising a main component with a specific refractive index and an additive having a different refractive index, where the difference is greater than or equal to 0.0050, dispersed as fine particles less than 50 μm, ensuring uniform phosphor distribution and preventing sedimentation, even without the use of fillers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If phosphor is added to curable resin composition for light wavelength conversion, then color rendering property can be adjusted, but phosphor sedimentation occurs due to density difference causing unstable color rendering
Solution Approach 1:
The patent applies the equipotentiality principle by matching the specific gravity of the curable resin composition to that of the phosphor particles. By adjusting the resin composition to have a specific gravity within 0.5-6.0 g/cm³ (preferably 2.0-5.0 g/cm³) to match the phosphor's specific gravity, the density difference is minimized, eliminating the sedimentation force and achieving stable phosphor dispersion throughout the encapsulant.
Solution Approach 2:
The patent employs parameter changes by modifying the specific gravity of the curable resin composition through formulation adjustments. By changing the resin base and additive composition to achieve a specific gravity range of 0.5-6.0 g/cm³, the physical parameter of the resin is optimized to prevent phosphor sedimentation while maintaining other required properties like transparency and curing characteristics.
2Power
If phosphor with larger specific gravity is used for light conversion, then light wavelength conversion efficiency is improved, but sedimentation during filling and curing process increases
Solution Approach 1:
The patent resolves this contradiction by making the curable resin composition's specific gravity equipotential with that of the phosphor particles. This eliminates the density-driven sedimentation force during filling and curing operations, allowing high-specific-gravity phosphor materials to be used without compromising manufacturing stability or causing concentration fluctuations in the dispensing process.
3Illumination intensity
If phosphor is dispersed in curable resin composition, then light emitting characteristics are determined, but concentration fluctuation occurs during dispensing causing color rendering fluctuation
Solution Approach 1:
The patent eliminates concentration fluctuation during dispensing by matching the specific gravity of the phosphor and resin composition. This equipotential condition prevents sedimentation that would otherwise cause varying phosphor concentrations at different dispensing times, ensuring uniform light emitting characteristics and color rendering throughout the manufacturing process.
4Stability of the object's composition
If filler is added to prevent phosphor sedimentation, then phosphor dispersion stability is improved, but heat resistance and light resistance deteriorate
Solution Approach 1:
The patent extracts and eliminates the need for filler materials by directly addressing the root cause of phosphor sedimentation - the specific gravity mismatch. By matching the resin composition's specific gravity to that of the phosphor, the invention achieves stable phosphor dispersion without introducing filler materials that would compromise heat and light resistance properties.
Solution Approach 2:
The patent changes the fundamental parameter of the resin composition - its specific gravity - to match that of the phosphor. This parameter adjustment eliminates sedimentation without requiring filler additives, thereby maintaining the intrinsic heat resistance and light resistance properties of the base resin system.
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 maintains consistent phosphor distribution and brightness, stabilizing color rendering properties throughout the manufacturing process, enhancing the handling and performance of photosemiconductor apparatuses.
Implementation Method 1
a curable resin composition which comprising: 100 parts by mass of a main component (X) (a refractive index: RIX) containing at least one of a silicone resin, a modified silicone resin, an epoxy resin and a modified epoxy resin, and exceeding 0 part by mass and 100 parts by mass or less of an additive (Y) (a refractive index: RIY) containing at least one of a silicone resin, a modified silicone resin, an epoxy resin and a modified epoxy resin, and having a different refractive index as that of the main component (X) being added and dispersed therein, wherein the difference of the refractive indexes of the main component (X) and the additive (Y) being |RIX−RIY|≧0.0050 in an uncured state
Data Source
AI summary
The invention provides a curable resin composition which comprising: 100 parts by mass of a main component (X) (a refractive index: RIX) containing at least one of a silicone resin, a modified silicone resin, an epoxy resin and a modified epoxy resin, and exceeding 0 part by mass and 100 parts by mass or less of an additive (Y) (a refractive index: RIY) containing at least one of a silicone resin, a modified silicone resin, an epoxy resin and a modified epoxy resin, and having a different refractive index as that of the main component (X) being added and dispersed therein, wherein the difference of the refractive indexes of the main component (X) and the additive (Y) being |RIX−RIY|≧0.0050 in an uncured state.