Hollow Light-Diffusing Particles in Silicone Resin Sealing
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Solution Overview
Problem
Conventional light-emitting devices using silicone-based resins for sealing face tackiness issues, leading to operational delays and device sticking problems due to adhesiveness, which existing solutions fail to adequately address.
Innovation Solution
Incorporating hollow light-diffusing particles with a size not smaller than 50 μm into the silicone resin, allowing them to float to the surface and form irregularities, reducing tackiness and improving light extraction efficiency by creating a rough surface on the light-transmissive member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silicone-based resin is used for sealing member, then heat resistance is improved, but tackiness increases causing operational delays and device sticking
Solution Approach 1:
The patent combines silicone-based resin with inorganic particles (such as SiO2, Al2O3, or TiO2) to create a composite sealing member material. This composite structure maintains the heat resistance of silicone resin while the inorganic particles reduce surface tackiness, preventing device sticking and operational delays. The inorganic particles are dispersed throughout the resin matrix to achieve both thermal stability and reduced adhesiveness.
Solution Approach 2:
The patent applies different properties to different regions of the sealing member. The inner region maintains high silicone content for heat resistance, while the surface region contains higher concentration of inorganic particles to reduce tackiness. This local differentiation allows the sealing member to simultaneously provide thermal protection and prevent sticking during handling and operation.
2Ease of operation
If microparticles are attached on silicone resin surface after curing, then tackiness is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates inorganic particles into the silicone resin before curing, rather than attaching them after curing. This preliminary incorporation simplifies the manufacturing process by eliminating separate steps for particle attachment. The particles are mixed into the uncured resin, which then cures as a unified composite material, reducing manufacturing complexity while still achieving tackiness reduction.
Solution Approach 2:
The patent merges the sealing function and the anti-tackiness function into a single integrated material system. The silicone resin provides sealing and heat resistance, while the embedded inorganic particles provide tackiness reduction. This combination eliminates the need for separate treatments or coatings, simplifying the overall manufacturing process.
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 solution effectively reduces tackiness, enhances light extraction efficiency, and prevents device sticking, while maintaining operational reliability and efficiency in manufacturing processes.
Implementation Method 1
causing the light-diffusing particles to float up to a surface of the injected silicone resin
Implementation Method 2
light-diffusing particles contained in the light-emitting element
Data Source
AI summary
A light-emitting device includes: a light-emitting element; a light-transmissive member that covers the light-emitting element; and a light-diffusing particles contained in the light-transmissive member. The light-diffusing particles are hollow and have a particle size not smaller than 50 μm. The light-transmissive member has a surface having irregularities associated with the light-diffusing particles. A method for manufacturing a light-emitting device includes steps of: mounting a light-emitting element in a recess of a base member; injecting a silicone resin containing light-diffusing particles into the recess, the light-diffusing particles having a particle size not smaller than 50 μm; causing the light-diffusing particles to float up to a surface of the injected silicone resin; and curing the injected silicone resin.