LED Package Silicon Oxide Reflector Hardness
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Solution Overview
Problem
Conventional light emitting diode (LED) packages face challenges with low hardness and light-extraction efficiency, which affect their reliability and stability, especially when using silicone as a reflector and encapsulant.
Innovation Solution
A light emitting device package is designed with a silicon-based polymer reflector and a silicon oxide layer, which enhances hardness and light-extraction efficiency, and includes a reflective metal layer covered by another silicon oxide layer to prevent discoloration and improve reflectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If silicone is used as a reflector and encapsulant, then ease of manufacture is improved, but hardness is insufficient
Solution Approach 1:
The patent uses a composite structure combining silicone base material with dispersed inorganic particles (such as silica, alumina, or titania particles with 0.1-10 μm diameter). This composite approach maintains the ease of manufacturing and molding properties of silicone while the inorganic particles provide enhanced hardness and mechanical strength to resolve the contradiction between ease of manufacture and hardness.
2Strength
If modified silicone with improved hardness is used, then hardness is improved, but light-extraction efficiency decreases
Solution Approach 1:
The patent applies local quality by dispersing inorganic particles selectively within the silicone matrix rather than uniformly modifying the entire silicone structure. The inorganic particles are concentrated in regions where mechanical strength is needed, while the silicone matrix maintains its optical transparency and light-extraction properties in regions where optical performance is critical, thus resolving the contradiction between hardness and light-extraction efficiency.
Solution Approach 2:
The patent utilizes the porous or particulate structure of dispersed inorganic materials within the silicone matrix. The inorganic particles create a heterogeneous structure that provides mechanical reinforcement without significantly blocking light transmission, as the particles are small (0.1-10 μm) and dispersed throughout the matrix, allowing light to pass through while gaining hardness.
3Stability of the object's composition
If reflector hardness is increased, then dimensional stability is improved, but light-extraction efficiency may be affected
Solution Approach 1:
The composite material system of silicone with dispersed inorganic particles provides dimensional stability through the rigid inorganic framework while maintaining light-extraction efficiency through the transparent silicone matrix. The inorganic particles (silica, alumina, or titania) have low thermal expansion and high stability, preventing deformation under thermal and mechanical stress, while the silicone ensures optical clarity and light extraction.
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 provides a light emitting device package with improved hardness, light-extraction efficiency, and dimensional stability, ensuring stable performance and increased reliability.
Implementation Method 1
a silicon oxide layer which is formed on a surface of the reflector
Implementation Method 2
improved light-extraction efficiency
Implementation Method 3
A hydroxyl group (—OH) may be included in at least a portion of the silicon oxide layer. The silicon oxide layer may have a hydrophilicity greater than a hydrophilicity of silicone.
Data Source
AI summary
A light emitting device package includes a substrate, a light emitting device disposed on the substrate, a reflector surrounding the light emitting device, and an encapsulant encapsulating the light emitting device. The reflector includes a silicon-based polymer which is a main body portion, and a silicon oxide layer disposed at least on a portion of a surface of the silicon-based polymer.