Light Emitting Element Sealing with Pre-Gelled Sealant
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Solution Overview
Problem
Existing methods for sealing light emitting elements using gel sealants face challenges such as air bubble formation, material limitations due to heat requirements, and inefficiencies in handling highly viscous gel precursors, particularly when using solvents that can decrease light output.
Innovation Solution
A method where the gel precursor gels before being applied, allowing for the use of highly viscous precursors and solvents, with reduced air bubble formation by pressing the gel sealant against the element under reduced pressure, and using a polyvinylidene-fluoride resin with a high refractive index to minimize refractive index differences and enhance brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two types of liquids are mixed and injected between the base and lid to form silicone gel, then the light emitting element is sealed, but air bubbles are mixed in causing decrease in light output
Solution Approach 1:
The gel precursor is caused to gel before being placed on the light emitting element. This preliminary gelling action transforms the precursor from a liquid state that can trap air bubbles during injection into a gel state that does not form air bubbles, thereby preventing the harmful effect while maintaining the sealing function
Solution Approach 2:
The physical state of the sealant material is changed from liquid to gel by causing the gel precursor to gel before application. This parameter change (from liquid to gel) eliminates the formation of air bubbles during the sealing process, resolving the contradiction between achieving reliable sealing and preventing air bubble formation that decreases light output
2Adaptability or versatility
If the gel precursor is highly viscous to allow use of solvents, then material flexibility is improved, but handling and injection becomes difficult
Solution Approach 1:
The gel precursor is caused to gel before being placed on the light emitting element. This preliminary gelling transforms the highly viscous precursor into a manageable gel form that can be easily handled and positioned, resolving the contradiction between material flexibility and ease of operation
Solution Approach 2:
The viscosity parameter of the sealant material is dramatically increased by causing the gel precursor to gel before application. This parameter change transforms the handling characteristics from difficult (highly viscous liquid) to easy (gel form), while maintaining the ability to use solvents in the precursor composition
3Reliability
If heat is applied to cause two types of liquids to gel, then the silicone gel is formed, but material selection is limited to heat-resistant materials
Solution Approach 1:
The gelling process is changed from heat-induced to a method that occurs before application, allowing the use of solvents and expanding material selection. By causing the gel precursor to gel before placement rather than applying heat after assembly, the invention enables use of heat-sensitive materials and solvents that would otherwise be incompatible
Solution Approach 2:
The gelling step is extracted from the post-assembly process and performed separately before the light emitting element is sealed. This separation allows the gel precursor to be processed independently, enabling the use of solvents and heat-sensitive materials without compromising the sealing integrity
4Reliability
If the lid is placed before gelling, then air bubbles can be prevented, but the gel precursor cannot be properly applied
Solution Approach 1:
The gel precursor is caused to gel before being placed on the light emitting element. This preliminary action ensures the material is in the correct gel state for application, allowing proper placement while preventing air bubble formation, thus resolving both requirements simultaneously
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
This method prevents air bubbles and allows for the use of solvents in gel precursors, eliminating the need for post-lid-affixing gelling, resulting in a brighter light emitting element module with improved handling and material flexibility.
Implementation Method 1
causing a gel precursor to gel to lose liquidity
Implementation Method 2
pressing the lid toward the light emitting element
Data Source
AI summary
Disclosed is a method for sealing a light-emitting device wherein formation of air bubbles in a light-emitting device module can be prevented by performing no gelation after fitting of a cover member. This method also enables to seal a light-emitting device by using a gel sealing material composed of a gel precursor which uses a solvent. Also disclosed is a light-emitting module formed by such a sealing method. In this method for sealing a light-emitting device, gelation of the gel precursor of a gel sealing material is performed before placing the precursor on the light-emitting device, and thus no gelation is necessary after fitting of a cover member. Consequently, a gel precursor having high viscosity that is difficult to be used in an injection method can be used in this method. Furthermore, a substance which requires use of a solvent can be used as a gel precursor of a gel sealing material. A light-emitting device module with high luminance wherein no air bubbles are included can be obtained by this method.