UV LED Package Optical Shielding Layer Resin Adhesive Reliability
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Solution Overview
Problem
Existing ultraviolet ray emitting packages face reliability issues due to chemical degradation of the resin adhesive layer caused by irradiation, leading to reduced adhesive ability and increased manufacturing costs with high-cost AuSn eutectic bonding layers.
Innovation Solution
Incorporation of an optical shielding layer between the resin adhesive layer and the ultraviolet ray transmitting window member, along with a protrusion on the window member to prevent irradiation and sliding, and strategic placement of the resin adhesive layer to minimize direct exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the resin adhesive layer is used to seal the ultraviolet ray transmitting window member, then the manufacturing cost is reduced compared to AuSn eutectic bonding, but the resin adhesive layer deteriorates due to ultraviolet ray irradiation causing chemical modification and loss of adhesive ability
Solution Approach 1:
An optical shielding layer is introduced as an intermediary between the ultraviolet ray transmitting window member and the resin adhesive layer. This shielding layer blocks ultraviolet rays from reaching the resin adhesive layer, preventing chemical modification and deterioration while allowing the resin to maintain its sealing function without requiring expensive AuSn eutectic bonding materials
Solution Approach 2:
The sealing structure is segmented into multiple functional layers: the ultraviolet ray transmitting window member, the optical shielding layer, and the resin adhesive layer. This segmentation allows each layer to perform its specific function - the shielding layer absorbs ultraviolet rays while the resin layer provides sealing - thereby preventing the deterioration problem while maintaining cost-effectiveness
2Device complexity
If the ultraviolet ray transmitting window member is directly adhered to the substrate, then the structure is simplified, but the window member slides along the traverse direction due to temporary viscosity reduction of the resin adhesive layer
Solution Approach 1:
A protrusion is added to the ultraviolet ray transmitting window member that fits into a corresponding recess on the substrate. This dimensional addition creates a mechanical interlock that prevents traverse sliding while maintaining the overall simplicity of the adhesive bonding structure
Solution Approach 2:
The protrusion and recess are pre-formed on the window member and substrate respectively, creating a mechanical constraint that prevents sliding before the resin adhesive layer fully cures and reaches its final strength
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 optical shielding layer reflects and absorbs ultraviolet rays, preventing chemical degradation of the resin adhesive layer, enhancing the reliability and reducing manufacturing costs by maintaining adhesive ability and preventing sliding issues.
Implementation Method 1
The optical shielding layer 12 is provided between the resin adhesive layer 11 and the deep-ultraviolet ray transmitting window member 10. Consequently, the deep-ultraviolet rays reflected within the deep-ultraviolet ray transmitting window member 10 are reflected and/or absorbed by the optical shielding layer 12
Implementation Method 2
the deep-ultraviolet rays reflected within the deep-ultraviolet ray transmitting window member 10 are reflected and/or absorbed by the optical shielding layer 12
Implementation Method 3
an ultraviolet ray emitting element provided within the recess of the substrate
Data Source
AI summary
An ultraviolet ray emitting package includes: a substrate having an upper portion defining a recess; an ultraviolet ray emitting element provided within the recess of the substrate; an ultraviolet ray transmitting window member provided on the upper portion of the substrate to cover the recess of the substrate; a resin adhesive layer provided between the upper portion of the substrate and the ultraviolet ray transmitting window member; and an optical shielding layer provided between the resin adhesive layer and the ultraviolet ray transmitting window member.