Anti-adhesion Fluoro-resin Layer for LED Handling
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Solution Overview
Problem
Light-emitting diodes (LEDs) face handling issues due to the sticky nature of their outer resin or material layers, which can cause adherence problems during transfer and handling processes.
Innovation Solution
A light-emitting device design incorporating a cover layer with a transparent binder and wavelength conversion particles, topped with an anti-adhesion layer containing fluoro-resin or fluoride compounds, which reduces surface energy and prevents adhesion, allowing for easier handling and release from pickup tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer layer is made of resin or sticky material for protection, then the light-emitting element is protected, but handling becomes difficult due to adhesion problems
Solution Approach 1:
The outer structure is divided into two distinct layers: a cover layer for protection and an anti-adhesion layer for easy handling. The cover layer (resin or sticky material) provides protection, while the separate anti-adhesion layer prevents sticking during handling, resolving the contradiction by segmenting the functional requirements into different layers.
Solution Approach 2:
The anti-adhesion layer acts as an intermediary between the protected light-emitting element and the external handling environment. It mediates the contradiction by providing a non-sticking surface that allows easy handling while the underlying cover layer maintains its protective function.
2Ease of operation
If an anti-adhesion layer is added to prevent sticking, then handling becomes easier, but device structure becomes more complex
Solution Approach 1:
The anti-adhesion layer is implemented as a thin film coating on the cover layer. This thin film approach provides the anti-adhesion functionality without adding significant structural complexity or volume, allowing easy handling while maintaining a relatively simple overall device structure.
3Strength
If the anti-adhesion layer has high hardness to prevent deformation, then structural integrity is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a hardness range (greater than the cover layer) for the anti-adhesion layer rather than a single fixed value. This parameter change approach allows flexibility in manufacturing while ensuring the anti-adhesion layer is sufficiently hard to prevent deformation, balancing structural integrity with manufacturing feasibility.
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 anti-adhesion layer effectively decreases the sticking force of the light-emitting device, enabling easier handling and preventing tool trapping, while maintaining a high hardness to prevent deformation and ensure reliable operation.
Implementation Method 1
an anti-adhesion layer which includes a flouro-resin or a fluoride compound and is disposed on the cover layer and the top surface as an outermost layer of the light-emitting device
Data Source
AI summary
A light-emitting device includes a light-emitting element, a cover layer, and an anti-adhesion layer. The light-emitting element has a top surface, a bottom surface and a side surface. The cover layer covers the light-emitting element and includes a first transparent binder. The anti-adhesion layer includes a flouro-resin or a fluoride compound and disposed on the cover layer and the top surface as an outermost layer of the light-emitting device. The anti-adhesion layer has a hardness greater than a hardness of the cover layer.