Reflective Layer Substrate for Light Emitting Element Modules
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Solution Overview
Problem
Substrates for light emitting elements with adhesive layers containing light shielding members fail to provide sufficient light resistance, particularly against blue light, leading to degradation and cohesive failures due to thickness and filler content limitations.
Innovation Solution
A substrate with a reflective layer between the resin substrate and the adhesive layer, containing a thermosetting resin and light reflective filler with 10% to 85% mass content, achieving 80% or more reflectance at 450 nm, which enhances light shielding while maintaining adhesive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the adhesive layer contains a light shielding member to shield light from the light emitting element, then light resistance is improved, but adhesive strength deteriorates due to cohesive failure when thickness exceeds 10 μm
Solution Approach 1:
The invention divides the light shielding function into two separate layers: a reflective layer (with high light reflectivity and low filler content) and an adhesive layer (with light shielding members). This segmentation allows each layer to optimize its thickness and composition for its specific function, preventing cohesive failure while maintaining light resistance.
Solution Approach 2:
The reflective layer acts as an intermediary between the light emitting element and the adhesive layer. It reflects light before it reaches the adhesive layer, reducing the light shielding burden on the adhesive layer and allowing the adhesive layer to maintain lower thickness and higher adhesive strength.
2Reliability
If the adhesive layer contains a light shielding member to shield light, then light resistance is improved, but adhesive property deteriorates due to peeling off at the interface when filler content exceeds several wt %
Solution Approach 1:
The invention separates the light shielding function from the adhesive function by creating a dedicated reflective layer. This allows the adhesive layer to contain minimal or no light shielding members, maintaining strong adhesion to the resin base material, while the reflective layer provides the necessary light shielding through its high reflectivity and controlled filler content.
Solution Approach 2:
The reflective layer is positioned specifically between the light emitting element and the adhesive layer, where light shielding is most needed. This localized approach allows the system to achieve overall light resistance without requiring high filler content throughout the entire adhesive structure, preserving adhesive properties.
3Reliability
If the adhesive layer thickness is increased to improve light shielding, then light resistance is improved, but cohesive failure occurs and adhesive property decreases
Solution Approach 1:
The invention segments the light shielding function into a separate reflective layer, allowing the adhesive layer to maintain optimal thickness (avoiding cohesive failure) while the reflective layer provides the necessary light shielding through its high reflectivity properties and controlled thickness.
Solution Approach 2:
The reflective layer serves as an intermediary that performs light shielding before light reaches the adhesive layer. This reduces the requirement for thick adhesive layers, allowing the adhesive layer to maintain lower thickness and avoid cohesive failure while still achieving sufficient overall light resistance.
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 substrate effectively shields blue light, preventing degradation and maintaining adhesive strength, thus improving the longevity and performance of light emitting element modules.
Implementation Method 1
a reflective layer which is disposed on the resin substrate and contains a thermosetting resin and a light reflective filler, wherein the content of the light reflective filler is 10% by mass or more and 85% by mass or less, and the reflectance at a wavelength of 450 nm is 80% or more
Data Source
AI summary
A substrate for a light emitting element including a resin substrate exhibiting flexibility and a metal wiring portion being formed on at least one surface side of the resin substrate via an adhesive layer, in which a reflective layer composed of a thermosetting resin is disposed between the resin substrate and the adhesive layer, in which the reflective layer contains a light reflective filler at 10% by mass or more and 85% by mass or less and has a reflectance to light at a wavelength of 450 nm of 80% or more.