Polyamide Reflector Composition for LED Packages
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Solution Overview
Problem
Existing polyamide compositions for LED reflectors lack high heat resistance, mechanical properties, and adhesion to sealing materials, leading to reduced reflectance and longevity when exposed to heat and light during LED package production and use.
Innovation Solution
A polyamide composition containing 30% or more of a high-melting-point polyamide (280°C or higher) and 30% or more titanium oxide, along with optional magnesium oxide and/or magnesium hydroxide, to enhance heat resistance, mechanical properties, and adhesion, while maintaining high reflectance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramics are used for reflectors, then heat resistance is improved, but productivity is reduced and initial reflectance is low
Solution Approach 1:
The patent changes the material parameters by using polyamide resin instead of ceramics, and optimizes the titanium oxide content (30-70 mass%) and particle size (0.1-5 μm) to achieve both high heat resistance and high reflectance while maintaining moldability and productivity
Solution Approach 2:
The patent creates a composite material system combining polyamide resin with titanium oxide particles, where the resin matrix provides heat resistance and structural integrity while the titanium oxide particles provide high reflectance, achieving properties superior to either material alone
2Productivity
If heat-resistant plastics are used for reflectors, then productivity is improved, but heat resistance and mechanical properties are insufficient when exposed to high temperatures
Solution Approach 1:
The patent selects polyamide resin with a melting point of 280°C or higher and optimizes the titanium oxide content (30-70 mass%) to achieve both moldability for high productivity and sufficient heat resistance for LED package applications
Solution Approach 2:
The patent combines polyamide resin with high含量的 titanium oxide (30-70 mass%) to create a composite that maintains the resin's moldability and productivity advantages while the titanium oxide enhances heat resistance and reflects light, preventing degradation at high temperatures
3Ease of manufacture
If heat-resistant plastics are used for reflectors, then ease of manufacture is improved, but adhesion to sealing material and mechanical properties deteriorate under thermal stress
Solution Approach 1:
The patent optimizes the titanium oxide particle size (0.1-5 μm) and content (30-70 mass%) to create a composite material that maintains good adhesion to sealing materials while providing sufficient mechanical strength and heat resistance for reliable LED package performance
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 composition achieves excellent adhesion, mechanical properties, and retains high reflectance even after exposure to heat and light, extending the life of LED light emitting devices and related lighting and image display devices.
Implementation Method 1
a high light reflectance (in particular, a high reflectance for light with a wavelength of around 460 nm)
Implementation Method 2
30 mass% or more of titanium oxide (B)
Data Source
Figure 1~2
Figure 3
AI summary
The present invention provides a polyamide composition for a reflector having high heat resistance and good mechanical properties, having excellent adhesion to a sealing material for an LED package, and capable of retaining a high reflectance even after exposure to heat and light intended for the production process of the LED package and the environment in which the reflector is used in the LED package, when it is molded. The present invention is a polyamide composition for a reflector, containing: 30 mass% or more of a polyamide (A) having a melting point of 280 °C or higher; and 25 mass% or more of titanium oxide (B). The total content of the polyamide (A) and the titanium oxide (B) is 75 mass% or more.