Solid Silicone Rubber LED Cover Preventing Fluorescent Powder Precipitation
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Solution Overview
Problem
Existing methods for producing LED fluorescent covers using liquid epoxy resin or silicone rubber are complex, costly, and suffer from non-uniform heat conduction, light emission, and high temperature resistance issues, with fluorescent powder often precipitating unevenly, affecting optical coherence and brightness consistency.
Innovation Solution
An LED fluorescent cover comprising 90-96% single-component solid silicone rubber, 3-8% fluorescent powder, and 1-2% vulcanizer, with a preparation method involving mixing and vulcanization steps to produce a uniform and efficient light-emitting product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid epoxy resin or liquid silicone rubber is used as base stock with fluorescent powder, then the fluorescent cover can be formed, but the fluorescent powder precipitates unevenly and the process becomes troublesome
Solution Approach 1:
The patent changes the physical state parameter of the silicone rubber from liquid to solid form. This parameter change fundamentally alters the interaction between the base material and fluorescent powder, preventing gravity-induced precipitation while maintaining formability through controlled melting during processing
Solution Approach 2:
The patent creates a composite material system where solid silicone rubber serves as the base stock combined with fluorescent powder. This composite approach allows the fluorescent powder to be uniformly distributed within the solid matrix, eliminating the precipitation issues seen in liquid systems while maintaining the desired optical and thermal properties
2Ease of manufacture
If the technique uses mixture of transparent colloid and fluorescent powder, then the fluorescent cover can be shaped, but the technique is complex and high in cost
Solution Approach 1:
The patent extracts and eliminates the complex multi-component mixture system (transparent colloid, various additives, and fluorescent powder) from the formulation. By using solid silicone rubber as a standalone base stock that inherently provides all necessary properties (viscosity control, adhesion, flexibility), the patent simplifies the manufacturing process while reducing costs
Solution Approach 2:
The solid silicone rubber base stock serves multiple functions simultaneously: it provides the structural matrix, controls viscosity during processing, ensures uniform fluorescent powder distribution, and eliminates the need for separate binding agents or stabilizers required in colloid-based systems
3Productivity
If liquid silicone rubber is used as base stock, then the fluorescent cover can be formed, but the efficiency is low and the process is troublesome
Solution Approach 1:
The patent employs preliminary action by pre-forming the fluorescent cover using solid silicone rubber as base stock before final assembly. The solid state allows for better handling, positioning, and integration with LED components, improving overall manufacturing efficiency while reducing the need for complex post-processing steps
Solution Approach 2:
By changing the base stock from liquid to solid silicone rubber, the patent improves manufacturing efficiency through better material handling properties, reduced contamination risks, and simplified processing steps, while eliminating the troubles associated with liquid material management
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 solution results in a low-cost, high-luminousness LED fluorescent cover with improved optical coherence and extended service life, overcoming the limitations of previous techniques by preventing fluorescent powder deposition and ensuring uniform light emission.
Implementation Method 1
1, mixing and standing: mixing the single-component solid silicone rubber, the fluorescent powder and the vulcanizer with an open mill or internal mixer, and standing for 2-4 h; 2, first vulcanization: controlling the temperature, pressure and vulcanization time of a vulcanizing machine... carrying out first vulcanization to the raw material
Implementation Method 2
The single-component solid silicone rubber... and 1-2% vulcanizer
Implementation Method 3
generating white light by using LED chip of blue light, or combination of LED chips of blue light and red light, together with fluorescent cover made by yellow fluorescent powder
Data Source
AI summary
A Light Emitting Diode (LED) fluorescent cover comprises the following components by weight: 90-96% of single-component solid silicone rubber, 3-8% of fluorescent powder and 1-2% of vulcanizer; and the preparation method includes the following steps: step 1): using mixed compound of the single-component solid silicone rubber, as well as the fluorescent powder and the vulcanizer as raw material to mix, standing for 2-4 h after mixing with open mill or internal mixer; step 2): controlling temperature, pressure and vulcanization time of vulcanizing machine according to size of the fluorescent cover mold, using the vulcanizing machine to carry out first vulcanization to the raw material that is obtained from the step 1) and placed in the fluorescent cover mold; step 3): with combined action of blower gun, taking the fluorescent cover out slowly; step 4): baking the semi-finished product in a closed space at a temperature of 150-200° C. for 1-2 h.