UV-Curable Optical Resin for LED Adhesion and Oxidation Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Light emitting diodes (LEDs) used in lighting applications, such as vehicle lamps, have a limited light emission angle, which restricts the design freedom and efficiency of the lamp due to their small size, and existing resins do not adequately address adhesion and oxidation issues with metal surfaces.
Innovation Solution
An optical resin comprising an oligomer, monomer, and additive, including glycidyl methacrylate (GMA) and a Hindered-Amine Light Stabilizer (HALS)-based stabilizer, is used to enhance adhesion, prevent oxidation, and improve the reliability of LEDs by forming a curable transparent resin layer that guides light and suppresses decomposition and discoloration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resins are used to seal the light emitting device, then the manufacturing process is simple, but adhesion to metal surfaces deteriorates and oxidation occurs
Solution Approach 1:
The patent uses a composite resin system combining oligomer, monomer, and additive components. Specifically, the oligomer provides base resin properties, the monomer enhances adhesion to metal surfaces, and the additive prevents oxidation. This composite approach resolves the contradiction by achieving superior adhesion and oxidation resistance while maintaining manufacturability through a multi-component formulation.
Solution Approach 2:
The patent modifies the chemical composition parameters of the resin by incorporating specific ratios of oligomer, monomer, and additive. By adjusting these compositional parameters, the resin achieves improved adhesion and oxidation resistance properties without significantly complicating the manufacturing process, as the changes are made at the material formulation level rather than the process level.
2Reliability
If the resin layer is made thicker to improve sealing, then adhesion improves, but light transmission and optical performance deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters of the resin to achieve both thick-layer sealing and good light transmission. By incorporating specific oligomer and monomer components with appropriate optical properties, the resin maintains high transparency even at greater thicknesses, thus resolving the contradiction between sealing effectiveness and optical performance.
3Reliability
If regular monomers are used in the resin, then the resin formulation is simple, but adhesion to metal surfaces deteriorates
Solution Approach 1:
The patent changes the chemical structure parameters of the monomer component by selecting specific monomers with functional groups that enhance metal surface adhesion. This targeted modification of monomer properties improves adhesion while keeping the overall formulation relatively simple, as only the monomer selection is optimized rather than the entire system.
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 resin layer improves the reliability and efficiency of LED-based lighting devices by increasing the light emission area, reducing oxidation, and maintaining optical stability, especially in high-temperature and high-humidity environments.
Implementation Method 1
the additive includes a photoinitiator of ultraviolet wavelength... a curable transparent resin cured by ultraviolet light
Implementation Method 2
the light stabilizer may include a Hindered-Amine Light Stabilizers (HALS)-based UV Stabilizer... suppresses decomposition and discoloration
Implementation Method 3
including glycidyl methacrylate (GMA)... adhesion and oxidation prevention may be improved
Data Source
AI summary
A lighting device disclosed in an embodiment of the invention includes a substrate; a light emitting device disposed on the substrate; a resin layer sealing the light emitting device on the substrate; and a diffusion layer or a reflective substrate disposed on the resin layer, wherein the resin layer includes an oligomer, a monomer, and an additive, wherein the monomer includes IBOA (Iso-bornyl Acrylate), two or more dilution monomers and glycidyl methacrylate (GMA), the additive includes a photoinitiator and an amine-based light stabilizer, and in the oligomer and the monomer, the content of glycidyl methacrylate is 10 to 15%, and the resin layer may be a curable transparent resin cured by ultraviolet light.