Transparent Silicone Epoxy for LED Packages
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Solution Overview
Problem
Conventional transparent molding compounds for LED packages, such as epoxy resin-anhydride compositions, suffer from thermal-yellowing and photo-yellowing under high temperature and UV radiation, leading to decreased efficiency and reliability, while silicone resins offer better durability but with poor mechanical properties and adherence issues.
Innovation Solution
A transparent silicone epoxy composition comprising epoxy modified siloxane, silanol-containing siloxane, and a catalyst, with a cross-linking reaction that enhances photothermal stability, heat durability, adherence, and air-barrier ability, using specific molecular weights and ratios to improve bonding energy and transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy resin-anhydride composition is used for transparent molding compound, then good mechanical property and low cost are achieved, but thermal-yellowing and photo-yellowing occur under high temperature and UV radiation
Solution Approach 1:
The patent uses a composite material system combining epoxy resin with silane-based additives (tetraethyl orthosilicate or methyl trimethoxysilane) to create a molding compound that maintains mechanical strength while achieving superior photothermal stability. The silane components react with the epoxy resin to form a cross-linked network that resists yellowing under UV radiation and high temperature, thus resolving the contradiction between mechanical property and photothermal stability.
2Stability of the object's composition
If silicone resin is used for high power LED packages, then good photo durability and heat durability are achieved, but poor mechanical property and tacky surface are obtained
Solution Approach 1:
The patent creates a composite material system where silane-based additives are integrated into the epoxy resin matrix. This composite approach allows the material to exhibit enhanced photo durability and heat durability similar to silicone resin, while maintaining the superior mechanical properties of epoxy resin. The cross-linked structure formed by silane reaction provides both durability and mechanical strength simultaneously.
Solution Approach 2:
The patent modifies the chemical composition parameters of the epoxy resin system by introducing specific silane compounds (tetraethyl orthosilicate or methyl trimethoxysilane) at controlled concentrations (0.1-5 wt%). This parameter change transforms the material properties to achieve both photo durability and mechanical strength, resolving the contradiction between these two characteristics.
3Ease of manufacture
If anhydride is used as curing agent, then low cost is achieved, but moisture sensitivity and degradation of physical nature occur
Solution Approach 1:
The patent introduces silane-based compounds (tetraethyl orthosilicate or methyl trimethoxysilane) as intermediary substances that modify the epoxy resin system. These intermediaries react with the epoxy resin to form a cross-linked network that reduces moisture sensitivity, thereby improving reliability while maintaining the cost-effectiveness of the anhydride curing 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 composition achieves high photothermal stability, heat durability, and adherence, maintaining transparency and mechanical properties under challenging conditions, addressing the limitations of existing materials for high-power LED applications.
Implementation Method 1
a cross-linking reaction of silanol-containing siloxane with (a) initiates
Implementation Method 2
high photothermal stability, heat durability... maintaining transparency and mechanical properties under challenging conditions
Data Source
AI summary
A transparent silicone epoxy composition is provided. The transparent silicone epoxy composition comprises (a) at least an epoxy modified siloxane, (b) at least a silanol-containing siloxane and (c) a catalyst. Each epoxy modified siloxane molecule comprises at least two cycloaliphatic epoxy groups and epoxy modified siloxane in the transparent silicone epoxy composition is about 10˜89 weight percentage. Silanol-containing siloxane can be cross-linked with epoxy modified siloxane. Silanol-containing siloxane comprises at least two hydroxyl groups. Silanol-containing siloxane in the transparent silicone epoxy composition is about 89˜10 weight percentage. The catalyst in the transparent silicone epoxy composition is about 0.01˜1 weight percentage.