Silicone Resin Composition for LED Encapsulation
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Solution Overview
Problem
Conventional silicone resin compositions used for encapsulating LEDs face issues with discoloration due to ultraviolet light and heat, poor crack resistance, high gas permeability, and erosion of silver-plated surfaces, which affect the brightness and reliability of LED devices.
Innovation Solution
A silicone resin composition comprising an organohydrogenpolysiloxane with a silphenylene skeleton, combined with a three-dimensional crosslinked organopolysiloxane and a linear organopolysiloxane, along with a hydrosilylation catalyst, to produce a cured product with improved Abbe's number, brightness, heat resistance, and reduced gas permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional epoxy resin is used for encapsulating LEDs, then crack resistance is improved, but discoloration occurs due to ultraviolet light and heat which decreases LED output power
Solution Approach 1:
The patent changes the chemical composition parameters by using a specific ratio of phenyl methyl siloxane (0.1-10 mol%) and diphenyl siloxane (1-20 mol%) units within the polysiloxane chain, transforming the material from conventional epoxy resin to a modified silicone resin that resists discoloration while maintaining mechanical properties
Solution Approach 2:
The patent creates a composite resin system combining polysiloxane base polymer with specific aromatic substituents (phenyl and diphenyl groups), forming a composite material that integrates the flexibility and UV resistance of silicone with the structural strength and optical stability of aromatic compounds
2Object-affected harmful factors
If a methyl silicone resin is used to prevent degradation of organic resin package, then light resistance and impact resistance are improved, but gas permeability increases which erodes silver plated surface and decreases brightness
Solution Approach 1:
The patent modifies the gas permeability parameter by controlling the molecular structure through specific mol% ratios of phenyl methyl siloxane and diphenyl siloxane units, creating a denser polymer network that reduces gas permeability while maintaining optical transparency and UV resistance
Solution Approach 2:
The patent introduces localized aromatic ring structures (phenyl and diphenyl groups) at specific positions within the polysiloxane chain, creating regions of high density and low gas permeability that selectively block gas transmission paths without affecting the overall optical properties
3Illumination intensity
If phenyl methyl siloxane unit is introduced to increase Abbe's number, then brightness is improved, but gas permeability remains high causing silver plated surface erosion
Solution Approach 1:
The patent merges the functions of phenyl methyl siloxane (providing high Abbe's number and brightness) with diphenyl siloxane (providing low gas permeability), creating a dual-functional resin system where both components work synergistically to achieve high brightness while protecting the silver plated surface
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 results in a cured product with enhanced brightness, reduced light dispersion, and improved heat and impact resistance, maintaining the integrity of the silver-plated surface and preventing discoloration, thus enhancing the reliability of LED devices.
Implementation Method 1
a silicone resin composition comprising (A-1) an organopolysiloxane having a three-dimensional crosslinked structure, i.e. resin structure, at least two alkenyl groups, and at least one monovalent aromatic hydrocarbon group bonded to a silicon atom, (A-2) a linear organopolysiloxane having alkenyl groups at at least both terminals of a molecular chain and at least one monovalent aromatic hydrocarbon group bonded to a silicon atom, (B-1) a linear organohydrogen polysiloxane having at least one silphenylene skeleton in a molecular chain and hydrosilyl groups at at least both terminals of the molecular chain
Data Source
AI summary
One purpose is to provide a silicone resin composition which provides a cured product having a large Abbe's number and a high brightness. A silicone resin composition including (A-1) an organopolysiloxane having a three-dimensional crosslinked structure, at least two alkenyl groups, and at least one monovalent aromatic hydrocarbon group bonded to a silicon atom, (A-2) a linear organopolysiloxane having alkenyl groups at at least both terminals of a molecular chain and at least one monovalent aromatic hydrocarbon group bonded to a silicon atom, (B-1) a linear organohydrogen polysiloxane having at least one silphenylene skeleton in a molecular chain and hydrosilyl groups at least both terminals of the molecular chain, in an amount such that a ratio of the number of the hydrosilyl groups in component (B-1) to a total number of the alkenyl groups in components (A-1) and (A-2) is 0.5 to 2, and (C) a hydrosilylation catalyst in a catalytic amount.