Silver LED Component Inorganic Oxide Coating Sulfur Resistance

Solution Overview

Problem

Conventional light emitting diode (LED) devices are susceptible to degradation from undesirable chemicals and chemical vapors, such as sulfur and chlorine-containing compounds, which can tarnish and corrode components, leading to reduced brightness and reliability.

Innovation Solution

The implementation of a protective barrier or layer, typically an inorganic oxide coating, is applied over components within the LED device to prevent harmful chemicals and vapors from interacting with silver or silver-alloyed components, thereby maintaining the optical and thermal properties of the device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional LED devices are used without protective coatings, then the device structure remains simple and manufacturing is easier, but the components become susceptible to tarnishing and corrosion from chemicals and chemical vapors, leading to reduced brightness and reliability

Engineering Contradiction:

Improvechemical resistanceVSAvoiddevice structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

An inorganic oxide coating is applied as an intermediary layer between the silver or silver-alloyed components and the harmful chemicals/chemical vapors. This coating acts as a protective barrier that prevents direct contact between the corrosive environment and the metal components, thereby preventing tarnishing and corrosion while maintaining device reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

A thin inorganic oxide film is deposited over the silver or silver-alloyed components to provide chemical protection. This thin film barrier is sufficient to prevent penetration by sulfur, chlorine, and other harmful chemicals while adding minimal complexity to the device structure and maintaining ease of manufacture.

Inventive Principle:

Principle #30Flexible shells and thin films

2Illumination intensity

If no protective barrier is applied, then manufacturing processes are simpler and cost is lower, but brightness retention deteriorates significantly in sulfur environments

Engineering Contradiction:

Improvebrightness retentionVSAvoidmanufacturing process

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The inorganic oxide coating serves as a protective intermediary that prevents harmful chemicals from reaching the silver components, thereby preserving their reflective properties and maintaining brightness retention in sulfur environments without significantly complicating the manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The application of an inorganic oxide coating changes the surface chemical properties of the silver components, making them resistant to sulfur and other harmful chemicals. This parameter change (adding a protective layer) ensures brightness retention while the manufacturing process remains relatively simple and cost-effective.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If protective inorganic oxide coating is applied, then chemical resistance and brightness retention improve significantly, but the device structure becomes more complex and manufacturing processes become more involved

Engineering Contradiction:

Improvebrightness retentionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

A thin inorganic oxide film is deposited over the silver or silver-alloyed components to provide chemical protection. This thin film barrier is sufficient to prevent penetration by sulfur, chlorine, and other harmful chemicals while adding minimal complexity to the device structure and maintaining ease of manufacture.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The application of an inorganic oxide coating changes the surface chemical properties of the silver components, making them resistant to sulfur and other harmful chemicals. This parameter change (adding a protective layer) ensures brightness retention while the manufacturing process remains relatively simple and cost-effective.

Inventive Principle:

Principle #35Parameter changes

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 solution significantly enhances the chemical resistance of LED devices, retaining approximately 95% or more of their initial brightness even in sulfur environments, compared to conventional devices which may retain only 60%, and prevents tarnishing and darkening of components.

Implementation Method 1

The implementation of a protective barrier or layer, typically an inorganic oxide coating, is applied over components within the LED device to prevent harmful chemicals and vapors from interacting with silver or silver-alloyed components

Methodology Applied

Scientific EffectPhysical barrier (coating): Coatings

Data Source

PatentUS11563156B2Light emitting devices and components having improved chemical resistance and related methods

Publication Date: 2023.01.24 CREELED INC

AI summary

Light emitting devices and components having excellent chemical resistance and related methods are disclosed. In one embodiment, a component of a light emitting device can include a silver (Ag) portion, which can be silver on a substrate, and a protective layer disposed over the Ag portion. The protective layer can at least partially include an inorganic material for increasing the chemical resistance of the Ag portion.