Curable Liquid Silicone Composition for Micro-LED Gap Filling
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Solution Overview
Problem
Existing high-refractive index liquid silicone compositions have high viscosity, making them difficult to inject into small gaps and resulting in process defects and sealing failures during injection molding for micro-LED devices, leading to lower production efficiency and device quality.
Innovation Solution
A curable liquid silicone composition with low viscosity (≤500 mPa·s) and high refractive index (≥1.47 at 847 nm) is formulated using organosilicon compounds with specific alkenyl and functional groups, along with a hydrosilylation reaction catalyst, enabling quick curing at room temperature or with heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a high-refractive index liquid silicone composition is used, then light extraction efficiency is improved, but viscosity increases making injection into small gaps difficult
Solution Approach 1:
The patent changes the chemical composition parameters of the silicone material by introducing specific aromatic groups (phenyl, tolyl, xylyl) and controlling the ratio of organopolysiloxane components to achieve both high refractive index (≥1.47 at 847 nm) and low viscosity (≤500 mPa·s), resolving the contradiction between optical performance and processability
Solution Approach 2:
The patent creates a composite silicone composition by combining multiple organopolysiloxane components with different molecular structures and functional groups, achieving a synergistic effect that provides both the required optical properties (high refractive index) and rheological properties (low viscosity for injection molding)
2Ease of operation
If the viscosity of the liquid silicone composition is reduced for easy injection, then injection capability is improved, but refractive index may decrease affecting light extraction efficiency
Solution Approach 1:
The patent simultaneously optimizes multiple compositional parameters including the types of aromatic groups, the number of silicon atoms in organopolysiloxane chains, and the ratio of different components to achieve the dual target of viscosity ≤500 mPa·s and refractive index ≥1.47 at 847 nm
3Strength
If conventional high viscosity composition is used for sealing, then sealing strength is improved, but gap filling capability deteriorates causing process defects
Solution Approach 1:
The patent changes the viscosity parameter to ≤500 mPa·s while maintaining adequate sealing strength through optimized compositional parameters, enabling both excellent gap filling capability in micro-LED devices and sufficient sealing performance
4Illumination intensity
If the refractive index is increased to reduce interfacial reflections, then light extraction efficiency is improved, but the composition becomes more difficult to process
Solution Approach 1:
The patent achieves refractive index ≥1.47 at 847 nm through specific compositional parameters while maintaining viscosity ≤500 mPa·s, ensuring both high light extraction efficiency and ease of processing via injection molding
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 facilitates gap filling in micro-LED devices, ensuring efficient sealing and enhancing light extraction efficiency by reducing interfacial reflections, thus improving production quality and yield.
Implementation Method 1
a curable liquid silicone composition, contains: (A) one or more types of organosilicon compound... having at least two alkenyl groups... (C) a compound having at least two silicon-bonded hydrogen atoms... (D) a hydrosilylation reaction catalyst
Data Source
AI summary
A photocurable liquid silicone composition, having a low viscosity that facilitates injection into a small gap, having a refractive index (pre-cure) that is high not only in a visible region but also in an infrared region, and that is particularly useful as a material for a device using an infrared LED light source, is provided. The composition comprises: (A): (A1) an organosilane or organopolysiloxane having 1 to 5 silicon atoms, having an alkenyl group, and having at least one monovalent functional group selected from aromatic groups and aralkyl groups, and/or (A2) an organopolysiloxane having 2 to 5 silicon atoms, having an alkenyl group, and not having a monovalent functional group selected from aromatic groups and aralkyl groups; (C) a compound having at least two silicon-bonded hydrogen atoms; and (D) a hydrosilylation reaction catalyst. Pre-cure, the refractive index of the entire liquid composition is ≥1.47, and the viscosity is ≤500 mPa·s.