Flexible Organosilicon Polymer for LED Light Conversion
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Solution Overview
Problem
Existing LED backlights and lighting devices face challenges in achieving consistent lightness, color coordinates, and color temperature due to the aging of fluorescent materials when exposed to heat, and the complexity of traditional packaging methods restricts shape flexibility and application.
Innovation Solution
A light-conversion flexible polymer material composed of organosilicon rubber, a diluting agent, and fluorescent materials, which are mixed and molded using cast molding and thermal curing, allowing for various shapes and improved heat resistance, with the fluorescent materials excited by a blue LED to produce white or other colors of light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If fluorescent materials are packaged close to the LED chip, then light conversion efficiency is improved, but the fluorescent materials are exposed to high temperature and age faster, reducing service life
Solution Approach 1:
The patent introduces an organosilicon rubber-based polymer material as an intermediary substance between the LED chip and fluorescent materials. This polymer material serves as a heat-resistant encapsulant that protects the fluorescent materials from high temperature exposure while maintaining their luminescent properties, thus resolving the contradiction between improving light conversion efficiency and extending service life
Solution Approach 2:
The patent changes the thermal and mechanical parameters of the packaging material by using organosilicon rubber with specific thermal stability and flexibility characteristics. This allows the packaging to withstand high temperatures near the LED chip without degrading the fluorescent materials, enabling close packaging for better light conversion while protecting against thermal aging
2Ease of manufacture
If traditional packaging methods are used, then manufacturing process is simple, but the shape of the packaged material cannot be changed and installation is restricted
Solution Approach 1:
The patent creates a flexible and deformable packaged structure using organosilicon rubber that can be bent and shaped after manufacturing. This dynamic characteristic allows the packaged LED module to adapt to various installation configurations and device shapes without requiring complex re-manufacturing processes
Solution Approach 2:
The patent employs a flexible polymer encapsulant made of organosilicon rubber that can be molded into various shapes and then deformed to fit different installation requirements. This flexible shell maintains the structural integrity and protection of internal components while enabling versatile installation options
3Reliability
If fluorescent materials are disposed at a certain distance from the light source, then heat-induced aging is avoided, but luminescent efficiency is reduced
Solution Approach 1:
The organosilicon rubber polymer acts as a thermal intermediary that allows the fluorescent materials to be positioned close to the light source for high luminescent efficiency while the polymer absorbs and dissipates heat, protecting the fluorescent materials from thermal damage and aging
4Loss of energy
If inorganic luminescent materials are used in photoluminescent films, then light conversion is achieved, but the process is complex and various shapes cannot be formed
Solution Approach 1:
The patent combines inorganic luminescent materials with organosilicon rubber polymer to create a composite packaged structure. This composite material integrates the light conversion capability of inorganic phosphors with the flexibility and ease of shaping of organic polymers, eliminating the need for complex separate film formation processes
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 flexible polymer material provides consistent and durable light emission, avoids heat-induced aging, and allows for flexible assembly, enhancing the service life and light conversion efficiency while simplifying the manufacturing process and enabling various product shapes.
Implementation Method 1
the fluorescent material in the molded photoluminescent material is excited by a blue LED to give out light, which, combined with the blue LED light, is white or other colors of light
Implementation Method 2
the mixture is molded by casting and thermal curing
Data Source
AI summary
A light-conversion flexible polymer material consists of an organic silicone rubber (bi-component addition thermal vulcanizing liquid silicone rubber, 20.0-75.0%), a diluting agent (silicone oil, 10.0-20.0%), a luminescent material (one or more of aluminate, silicate, siliconitride and oxysulfide luminescent materials, 15.0-65.0%) and auxiliary. The polymer material can be bent randomly as required. The polymer material is made by mixing raw materials uniformly in a blending container, inpouring the obtained mixture into a mold and thermal-curing. The polymer material is used on the surface of a blue-light LED and the luminescent material in the light-conversion flexible polymer material can be excitated by light emitted from the blue light LED to give out light, which is combined with residual blue light into white light. The polymer material can be widely used in light-source devices such as lamp, nixie tube and backlight.