LED Device Dual-Layer Sealant Brightness

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Solution Overview

Problem

Existing LED devices face challenges in enhancing light emission and display effects due to limitations in the design of the LED bracket, LED chip, and encapsulation sealant.

Innovation Solution

The LED device incorporates a metal bracket with a reflective cup cover, an under sealant with high light transmittance, and a surface sealant with a matte effect, where the under sealant covers the LED chip and the surface sealant covers the under sealant, achieving a high brightness and matte effect.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a single encapsulation sealant is used, then the manufacturing process is simple, but the light emission effect and display effect are insufficient

Engineering Contradiction:
Improvelight emission effectVSAvoidencapsulation sealant structure
Core Design Contradiction:
Illumination intensityVSDevice complexity

Solution Approach 1:

The encapsulation sealant is divided into two distinct layers: a lower encapsulation sealant layer and an upper encapsulation sealant layer. Each layer serves different functions - the lower layer provides structural support and stress relief, while the upper layer optimizes light emission and display effects. This segmentation allows each layer to be optimized independently for its specific function, resolving the contradiction between performance and complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Different regions of the encapsulation sealant are assigned different properties. The lower encapsulation sealant layer has properties optimized for stress management and structural integrity, while the upper encapsulation sealant layer has properties optimized for light transmission and display quality. This local differentiation of material properties enables simultaneous optimization of multiple performance aspects without requiring complete structural redesign.

Inventive Principle:
Principle #3Local quality

2Illumination intensity

If the encapsulation sealant has high light transmittance, then brightness is improved, but the matte effect is reduced

Engineering Contradiction:
ImprovebrightnessVSAvoidmatte effect
Core Design Contradiction:
Illumination intensityVSShape

Solution Approach 1:

The encapsulation sealant is segmented into two layers with different optical properties. The lower encapsulation sealant layer uses a transparent material with high light transmittance to maximize brightness and light emission. The upper encapsulation sealant layer uses a translucent material with a matte effect to provide the desired visual appearance. This segmentation allows both high brightness and matte effect to coexist in different spatial zones.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The solution moves from a single-dimensional consideration (either transparent or translucent) to a two-dimensional layered structure. By stacking layers with different optical properties vertically, the patent achieves both high light transmittance in the lower layer and matte effect in the upper layer, effectively resolving the contradiction through dimensional expansion of the design space.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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 combination of transparent under sealant and matte surface sealant enhances light transmittance and diffuse reflection, resulting in high brightness and low stress with improved light emission and display effects.

Implementation Method 1

the cup cover includes a reflective cup having a cavity

Methodology Applied
Scientific EffectReflection: Reflection

Implementation Method 2

the under sealant is a transparent layer

Methodology Applied
Scientific EffectLight transmittance:

Implementation Method 3

the surface sealant is a matte layer

Methodology Applied
Scientific EffectDiffuse reflection: Scattering

Data Source

PatentUS10297730B2LED device, method for manufacturing an LED device, and LED display module
Publication Date: 2019.05.21 FOSHAN NATIONSTAR OPTOELECTRONICS CO LTD
  • US10297730B2 patent drawing
  • US10297730B2 patent drawing

AI summary

An LED device, a method for manufacturing an LED device, and an LED display module are provided. The LED device includes an LED bracket, an LED chip and an encapsulation sealant. The LED bracket includes a metal bracket and a cup cover encasing the metal bracket. The cup cover includes a reflective cup having a cavity. The LED chip is fixed in the cavity of the reflective cup. The cavity of the reflective cup is filled with the encapsulation sealant. The encapsulation sealant includes an under sealant and a surface sealant. The under sealant covers the LED chip, and the surface sealant covers the under sealant. The under sealant is a transparent layer. The surface sealant is a matte layer.