LED Housing Fluoropolymer Coating Light Extraction
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Solution Overview
Problem
Existing LED housing technologies face challenges in improving light extraction efficiency due to internal reflections and the use of titanium dioxide, which causes the housing to become yellowish, and the high cost of fluoro-containing engineering plastics.
Innovation Solution
A fluoropolymer surface coating layer is applied to a housing body made of non-fluoro-containing polymer engineering plastics, using a dispersion that includes homopolymers or copolymers of fluoropolymers, allowing for reduced fluoropolymer usage and maintaining reflectivity while being compatible with existing manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If titanium dioxide-containing PPA housing is used to improve light extraction efficiency, then reflectivity to visible light is improved, but the housing gradually becomes yellowish and light extraction efficiency is reduced
Solution Approach 1:
The patent extracts the fluoropolymer coating as a separate functional layer from the housing material itself. By applying fluoropolymer dispersion as a surface coating on PPA housing, the reflectivity function is separated from the structural material, allowing the housing to maintain its original color stability while the coating provides the light extraction enhancement.
Solution Approach 2:
The patent creates a composite structure combining PPA housing material with fluoropolymer surface coating. This composite approach allows the base PPA material to provide structural integrity and color stability, while the fluoropolymer coating layer provides the light extraction efficiency improvement through its reflective properties.
2Stability of the object's composition
If fluoro-containing engineering plastics are used to make housing to avoid yellowing, then color stability is improved, but manufacturing cost significantly increases
Solution Approach 1:
The patent extracts only the essential fluoropolymer coating function from the expensive fluoro-containing engineering plastics. By applying a thin fluoropolymer dispersion coating on conventional PPA housing, the color stability benefit is achieved without requiring the entire housing to be made from expensive fluoro-containing materials, thus significantly reducing manufacturing cost.
Solution Approach 2:
The patent uses a cost-effective approach by applying a relatively thin fluoropolymer coating layer rather than using expensive fluoro-containing engineering plastics for the entire housing. This reduces the quantity of expensive fluoropolymer material needed while still achieving the desired color stability and light extraction performance.
3Illumination intensity
If fluoropolymer coating layer is applied to housing body, then light extraction efficiency is improved and color stability is maintained, but the complexity of manufacturing process increases
Solution Approach 1:
The patent employs a self-service approach where the fluoropolymer coating process is designed to be compatible with existing housing manufacturing workflows. The coating can be applied directly to the molded housing parts using standard coating equipment, and the coating process itself serves to both protect the housing and provide the light extraction enhancement function.
Solution Approach 2:
The patent optimizes the fluoropolymer dispersion formulation and coating parameters to achieve uniform coverage at minimal thickness. By controlling coating thickness, solvent content, and curing conditions, the process achieves the desired optical performance without requiring complex multi-step manufacturing procedures.
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 enhances light extraction efficiency by reflecting visible light and maintaining a stable color, while reducing manufacturing costs by utilizing market-available materials and allowing for thermal processing, thus improving the usability and resource efficiency of LED devices.
Implementation Method 1
the fluoropolymer surface coating layer has a stable color, is capable of reflecting visible light
Implementation Method 2
the fluoropolymer surface coating layer is formed by coating fluoropolymer dispersion on the housing body
Implementation Method 3
can be subjected to the welding process at a temperature from 260° C. to 280° C. for more than 3 minutes
Data Source
AI summary
A housing for supporting a light-emitting diode chip is disclosed. The housing includes a housing body made of non-fluoro-containing polymer and a surface coating layer covering at least a portion of the housing body. The surface coating layer is made of fluoropolymer dispersion and provided for reflecting light emitted from a light-emitting diode chip disposed on the housing body. A structure of light-emitting diode including the housing and a light-emitting diode chip is also disclosed.