Phosphor-Containing Cured Silicone for Uniform LED Chromaticity
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Solution Overview
Problem
Existing methods for producing LED light-emitting members with uniform chromaticity face challenges such as insufficient phosphor dispersion, low transparency, and high production costs, along with complex processes and the need for special particles, which result in chromaticity deviations and increased costs.
Innovation Solution
A phosphor-containing cured silicone is developed using a composition comprising specific silicone components and particles, which are uniformly dispersed through hydrosilylation, allowing for the production of LED light-emitting members with improved thermal resistance, lightfastness, and reduced chromaticity deviations at a lower cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If silica particles are used to improve hardness and cold/heat shock resistance, then strength is improved, but phosphor precipitation occurs and transparency deteriorates
Solution Approach 1:
The patent introduces organopolysiloxane-grafted silica particles as an intermediary substance. The organopolysiloxane coating on the silica particle surface acts as a mediator that prevents direct interaction between phosphor and silica, thereby preventing phosphor precipitation while maintaining the strength-enhancing properties of silica particles.
Solution Approach 2:
The patent creates a composite material system consisting of silica particles with grafted organopolysiloxane chains. This composite structure combines the strength benefits of silica with the dispersion-stabilizing properties of organopolysiloxane, achieving both high strength and uniform phosphor dispersion.
2Ease of manufacture
If conventional silicone-based materials are used for phosphor dispersion, then ease of manufacture is maintained, but transparency and phosphor dispersion uniformity deteriorate
Solution Approach 1:
The patent modifies the chemical parameters of the silicone-based material by incorporating organopolysiloxane-grafted silica particles. This parameter change alters the interaction characteristics between the matrix and phosphor, preventing precipitation and improving chromaticity uniformity while maintaining manufacturing simplicity.
3Manufacturing precision
If LED modules are classified to reduce chromaticity deviation, then chromaticity uniformity is improved, but productivity decreases due to complex classification processes
Solution Approach 1:
The patent applies preliminary action by ensuring uniform phosphor dispersion in the silicone-based material before LED module assembly. This preliminary uniformity prevents chromaticity deviations from occurring in the first place, eliminating the need for subsequent classification processes and maintaining high productivity.
Solution Approach 2:
The patent extracts the chromaticity control problem from the assembly process by solving it at the material level. Instead of controlling chromaticity through classification of finished modules, the invention embeds chromaticity uniformity directly into the silicone-based material composition, removing the need for complex classification operations.
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 enables the uniform dispersion of phosphors in silicone, reducing chromaticity deviations and production costs, while maintaining high thermal resistance and lightfastness, allowing for the manufacture of LED light-emitting members with improved optical characteristics without the need for complex classification processes.
Implementation Method 1
cured by hydrosilylation
Data Source
AI summary
A phosphor-containing cured silicone that is a cured silicone which has a structure represented by general formulae (1) and/or (2) and also has units selected from general formulae (3) and/or (4), the phosphor-containing cured silicone includes a phosphor and particles having units selected from general formulae (3) and/or (4):wherein R1 to R3 are each a hydrogen atom, a methyl group, an ethyl group or a propyl group; X represents a methylene group, a dimethylene group or a trimethylene group, and may be the same or different; and R4 to R6 are each a substituted or unsubstituted monovalent hydrocarbon group, and may be the same or different.An object of the present invention is to provide a cured silicone in which a phosphor is uniformly dispersed, the cured silicone is characterized in that a silicone material has good thermal resistance and lightfastness. In addition, an object of the present invention is to provide a process for production of an LED-mounted substrate by which a plurality of LED elements can be continuously mounted in a batch manner.