Nanoparticle-Enhanced Resin Bonding for LED Light Extraction
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Solution Overview
Problem
Existing light-emitting devices face challenges in achieving stable bonding and high light extraction efficiency due to issues with the bonding member's shape and light transmission.
Innovation Solution
A light-emitting device design incorporating a bonding member made of resin with nanoparticles, where the nanoparticles have specific diameter and content ranges, forming a stable fillet shape that enhances bonding and light extraction efficiency by reducing resin dripping and light scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding members are used to bond the light-emitting element and light-transmissive member, then bonding is achieved, but the fillet shape is unstable and light extraction efficiency is reduced due to resin dripping and light scattering
Solution Approach 1:
The bonding member uses a composite material consisting of resin and transparent oxide particles (such as silica or alumina) with specific particle diameters (0.1 μm to 10 μm). This composite structure provides both stable bonding properties and improved light extraction efficiency by reducing light scattering while maintaining fillet shape stability during the bonding process
Solution Approach 2:
The invention specifies precise parameter ranges for the oxide particles including particle diameter (0.1 μm to 10 μm) and content (5 mass% to 50 mass%). By optimizing these parameters, the bonding member achieves stable fillet formation without excessive resin dripping while simultaneously improving light extraction efficiency through controlled light scattering properties
2Illumination intensity
If nanoparticle content is increased to improve light extraction efficiency, then luminous flux increases, but resin viscosity changes affecting fillet shape stability
Solution Approach 1:
The invention optimizes the nanoparticle content within specific ranges (5 mass% to 50 mass%) to balance two competing requirements: increasing light extraction efficiency (and thus luminous flux) while maintaining appropriate resin viscosity for stable fillet formation. This parameter optimization ensures that the resin remains workable during bonding while providing sufficient light scattering enhancement
3Area of stationary object
If resin is applied generously to ensure complete coverage during bonding, then bonding coverage is improved, but excessive resin dripping occurs causing unstable fillet shape
Solution Approach 1:
The addition of oxide particles to the resin creates a composite material with modified rheological properties. This composite structure allows the bonding member to maintain adequate coverage area while the particle reinforcement reduces excessive resin flow and dripping, resulting in stable fillet shape formation during the bonding process
Solution Approach 2:
The oxide particle content (5 mass% to 50 mass%) and particle diameter (0.1 μm to 10 μm) are optimized to achieve the right balance between coverage and shape stability. The particles increase the effective viscosity and structural integrity of the bonding member, preventing excessive dripping while ensuring complete coverage of the bonding area
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 results in a light-emitting device with improved bonding strength and light extraction efficiency, increasing luminous flux and maintaining a stable fillet shape, while minimizing unnecessary light scattering.
Implementation Method 1
The bonding member is made of a resin that contains nanoparticles. The nanoparticles have a particle diameter of 1 nm or more and 30 nm or less and a content of 10 mass % or more and 20 mass % or less
Data Source
AI summary
A light-emitting device includes: a light-emitting element including a first surface provided as a light extraction surface, a second surface opposite to the first surface, a plurality of third surfaces between the first surface and the second surface, and a positive electrode and a negative electrode at the second surface; a light-transmissive member disposed at the first surface; and a bonding member disposed between the light-emitting element and the light-transmissive member and covering from the first surface to the plurality of third surfaces of the light-emitting element to bond the light-emitting element and the light-transmissive member. The bonding member is made of a resin that contains nanoparticles. The nanoparticles have a particle diameter of 1 nm or more and 30 nm or less and a content of 10 mass % or more and 20 mass % or less.