Siloxane Resin Vapor-Phase Curing for Stable LED Encapsulation
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Solution Overview
Problem
The curing of siloxane polymers and resins in LED manufacturing is often incomplete, unstable, and prone to thermal and photothermal aging, leading to brittleness and defects in light emitting devices, with existing methods failing to provide reproducible and controlled curing processes.
Innovation Solution
A method involving vapor phase catalysis using catalysts like 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), bis(dimethylamino)diethylsilane (Bis-DMADES), and aminopropyl trimethoxysilane (APTMS) to catalyze the curing of uncured siloxane polymers, either alone or in combination with plasma exposure, allowing for controlled crosslinking and inhibition of post-curing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If normal curing methods are used for siloxane polymers, then the polymer can be cured, but the curing process continues long after devices are sold and put into use, causing thermal and photothermal aging that changes the polymer from flexible to brittle
Solution Approach 1:
The patent introduces a vapor-phase catalyst as an intermediary substance that mediates the curing process. The catalyst is applied in vapor form and allows controlled curing without residual catalytic activity that would cause post-curing aging. This intermediary enables complete curing while preventing the harmful continued reactions that lead to brittleness.
Solution Approach 2:
The patent changes the physical state of the catalyst from liquid or solid to vapor phase, and controls parameters such as temperature, humidity, and catalyst concentration to achieve complete curing without residual activity. By controlling the vapor phase catalyst parameters, the process achieves thorough curing while preventing post-curing degradation.
2Stability of the object's composition
If incomplete or insufficient curing is used, then the polymer remains flexible, but the result is unstable with limited shelf life and service life
Solution Approach 1:
The vapor-phase catalyst acts as a controlled intermediary that ensures complete and uniform curing throughout the polymer matrix. The vapor phase allows the catalyst to penetrate and distribute evenly, achieving stable curing without the instability associated with incomplete curing, while avoiding the brittleness of over-curing.
3Manufacturing precision
If traditional liquid or solid catalysts are used, then curing can occur, but the process is difficult to control and may result in uneven hardening
Solution Approach 1:
The patent utilizes the phase transition of the catalyst from liquid/solid to vapor state. This phase transition enables the catalyst to diffuse uniformly throughout the polymer, ensuring even hardening. The vapor phase naturally distributes the catalyst evenly, simplifying process control while achieving high manufacturing precision.
Solution Approach 2:
The patent employs vapor phase delivery of the catalyst, utilizing gas-phase transport mechanisms. The vapor-phase catalyst can be introduced and distributed through the polymer matrix using pneumatic principles, enabling controlled and uniform curing without the complexity of liquid or solid catalyst handling.
4Manufacturing precision
If high temperature and long time curing is used, then complete curing is achieved, but the polymer becomes brittle and cracks due to stress
Solution Approach 1:
The patent changes the curing parameters by using vapor phase catalysts at controlled temperatures and humidities. This alternative parameter regime achieves complete curing without the high temperatures and long times that cause stress and brittleness. The vapor phase catalyst enables curing at milder conditions while maintaining completeness.
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
This approach enables rapid curing at lower temperatures and in shorter times, improving the thermo-mechanical stability of the polymers and preventing embrittlement, thus enhancing the reliability and shelf life of LED devices.
Implementation Method 1
contacting a material with a first catalyst in a vapor phase, the material comprising: an uncured polymer; optionally a second catalyst; and particles that inhibit the second catalyst; and (during or) after said contacting a material, curing the uncured polymer
Implementation Method 2
curing comprises causing one of ring-opening polymerization and condensation polymerization
Implementation Method 3
curing comprises causing one of ring-opening polymerization and condensation polymerization
Implementation Method 4
either alone or in combination with plasma exposure
Data Source
AI summary
The present invention encompasses materials and methods for catalyzing the cross-linking and curing of siloxane polymers. In particular, the present disclosure provides materials, methods, and conditions for vapor phase catalysis for curing organosiloxane polymers and resins, including resin linear organosiloxane block copolymers, as well as the incorporation of those methods into processes for making light emitting devices, including light emitting diodes.