Non-Hermetic LED System with Active Composition for Contaminant Removal
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Solution Overview
Problem
LED systems face performance decay and reliability issues due to the penetration of sulfur and halogen compounds, such as chlorine, which can diffuse and react with internal components, causing optical and electrical property changes, even when the systems are not hermetically sealed, leading to accelerated degradation.
Innovation Solution
Incorporating an active composition with materials like active carbons, silver, copper, zinc, copper oxide, zinc oxide, and silver oxide in powder form within the LED system, specifically designed to remove noxious substances, allowing for controlled gas exchange and moisture management, thereby preventing the ingress of sulfur and halogen compounds while avoiding the need for additional moisture getters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If LED systems are not hermetically sealed to allow gas exchange, then moisture management is improved, but sulfur and halogen compounds can penetrate and cause performance decay
Solution Approach 1:
An active composition is introduced as an intermediary substance within the LED system that selectively interacts with noxious gases. This composition acts as a mediator between the external environment and internal LED components, capturing sulfur and halogen compounds through adsorption and chemical reaction while allowing the system to maintain a non-hermetic structure for moisture management.
Solution Approach 2:
The invention changes the chemical parameters of the internal environment by introducing reactive materials (silver, copper, zinc, and their oxides) that alter the interaction between penetrating gases and LED components. These materials transform harmful sulfur and halogen compounds into stable compounds through chemical reactions, changing the chemical composition and reactivity of the internal atmosphere.
2Reliability
If sulfur and halogen releasing materials are avoided in LED system design, then reliability is improved, but manufacturing constraints and costs increase
Solution Approach 1:
The harmful function of sulfur and halogen releasing materials is extracted and removed from the LED system design. Instead of requiring all components to be free of these materials, the invention introduces a dedicated active composition that specifically targets and removes these contaminants, allowing standard materials to be used while achieving the same reliability outcome.
Solution Approach 2:
The invention converts the potential harm of sulfur and halogen compounds into a benefit by using the active composition to trap and neutralize these substances. The materials that would normally cause degradation (silver, copper, zinc) are now beneficial as they actively scavenge contaminants, transforming the problem of contaminant penetration into a protective mechanism.
3Reliability
If active composition is added to remove noxious substances, then reliability is improved, but device complexity increases
Solution Approach 1:
The active composition is merged with existing LED system components rather than being added as a separate complex subsystem. The composition can be integrated into the encapsulant, mounted on existing structures, or incorporated into housing materials, combining the contamination removal function with structural or protective elements already present in the LED system.
Solution Approach 2:
The active composition provides multiple functions simultaneously: it acts as a contaminant trap for sulfur and halogen compounds, serves as a protective barrier for internal components, and can contribute to the structural or optical properties of the LED system. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
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 removes gaseous noxious species, preventing performance decay and allowing for a more reliable and cost-effective LED system design, with improved resistance to contaminants and reduced manufacturing constraints, maintaining performance even at elevated temperatures.
Implementation Method 1
the active composition is used for the removal of noxious substances such as sulfur or halogens
Implementation Method 2
sulfur or halogens... can diffuse in the whole system reacting with the reflecting silver-coated surfaces, blackening them, or reacting with silver contacts leading to the formation of Ag 2 S and AgCl
Data Source
AI summary
Non-hermetically sealed LED system containing an active composition whose amount is comprised between 0,06 and 2,5 mg per cm2 of the system optical window area,the active composition containing an active material in powder form, wherein at least 75 wt% of said active material is chosen from one or more of active carbons, silver, copper, zinc, copper oxide, zinc oxide,calcium oxide, silver oxide.