Thermosetting Composition Viscosity Control for LED Moldability
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Solution Overview
Problem
The existing methods for producing light-emitting devices using thermosetting resins face challenges with poor fluidity of thermoset resin liquids, leading to issues like unfilling, void formation, and burrs during the molding process, which affect the mass producibility and quality of the devices.
Innovation Solution
A thermosetting composition comprising a (meth)acrylate compound with a specific viscosity, spherical silica, and a white pigment, along with optional additives, is developed to achieve optimal shear viscosity and improved moldability, preventing unfilling, voids, and burrs in the molded products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If titanium oxide as a representative white pigment is used, then heat resistance and weatherability are improved, but viscosity increases and fluidity deteriorates
Solution Approach 1:
The patent changes the particle size parameter of the white pigment to 3-10 μm (specifically 4-6 μm preferred) and controls the viscosity of the (meth)acrylate compound to 1-300 mPa·s, achieving optimal balance between heat resistance and fluidity for mass production
Solution Approach 2:
The patent creates a composite thermosetting composition combining (meth)acrylate compound, spherical silica filler, and white pigment in specific ratios, achieving improved heat resistance and weatherability while maintaining appropriate viscosity through the composite structure
2Reliability
If titanium oxide as a representative white pigment is used, then heat resistance and weatherability are improved, but fluidity of the thermoset resin liquid deteriorates
Solution Approach 1:
The patent optimizes the particle size parameter of white pigment to 3-10 μm and controls the viscosity parameter of the (meth)acrylate compound to 1-300 mPa·s, achieving the right balance between weatherability and fluidity for continuous molding
Solution Approach 2:
The patent develops a composite thermosetting composition with specific ratios of (meth)acrylate compound, spherical silica, and white pigment, where the composite structure maintains fluidity while providing weatherability
3Productivity
If the fluidity of the liquid is poor, then mass producibility becomes insufficient due to bending or un-filling, but improving fluidity may affect continuous moldability
Solution Approach 1:
The patent precisely controls the viscosity parameter of the (meth)acrylate compound to 1-300 mPa·s and particle size of white pigment to 3-10 μm, achieving optimal fluidity that enables both mass production efficiency and continuous molding capability
Solution Approach 2:
The patent applies spherical silica with specific surface properties and controlled white pigment particle size to create local optimization in the composition, ensuring proper flow during injection while maintaining moldability for continuous production
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 ensures excellent continuous moldability, preventing unfilling, void formation, and burr creation, thereby enhancing the quality and mass producibility of light-emitting devices while maintaining high reflectance and heat resistance.
Implementation Method 1
a thermosetting composition comprising the following components (A) to (C)... (A) a (meth)acrylate compound
Implementation Method 2
spherical silica; and (C) a white pigment... has a shear viscosity at 25° C. and 10 s−1 of 1 Pa·s or more and 500 Pa·s or less
Data Source
AI summary
A thermosetting composition comprising: (A) a (meth)acrylate compound having a viscosity at 25° C. of 1 to 300 mPa·s with which a substituted or unsubstituted aliphatic hydrocarbon group including 6 or more carbon atoms is ester-bonded; (B) spherical silica; and (C) a white pigment, and having a shear viscosity at 25° C. and 10 s−1 of 1 Pa·s or more and 500 Pa·s or less and a shear velocity at 25° C. and 100 s−1 of 0.3 Pa·s or more and 100 Pa·s or less.