As a solid-state semiconductor light-emitting device, LED is gradually replacing traditional light-emitting devices in various application scenarios. LED of high power, high energy efficiency, high brightness, and high reliability also requires LED packaging materials with the better optical properties, mechanical properties, and weather resistance.
The hardness of silicone materials in LED encapsulation is merely 50 ~ 70 shore A (about 30 ~ 40 shore D). And there is no silicone materials for LED packaging have been reported with a hardness over 80 Shore D until now[1–4]. The higher hardness of the material can protect LED device from damage caused by external impact more effectively. The refractive index of LED packaging materials largely determines the light extraction efficiency of LED. The refractive index of common packaging materials is generally between 1.4 and 1.5 and much lower than that of general GaN light-emitting chips (RI ≈ 2.45)[5, 6]. The difference in the refractive index between LED chip and packaging materials results in total reflection at the interface, which leads to light loss and reduced luminous efficiency of the device[7, 8].
The introduction of inorganic nanoparticles with a high refractive index is the most direct method to prepare materials with a high refractive index and high hardness[9, 10]. However, the nanoparticles gradually agglomerate, thus significantly affecting the light transmittance of the materials, so the materials can‘t be preserved for a long time. In addition, the added filler also increases the viscosity of the curing system sharply and decreases the fluidity, thus affecting subsequent processing steps.
The properties of addition-curing silicone materials can be adjusted by changing the molecular structures of two polysiloxanes. Due to the high ratio of dielectric polarizability to molar volume, phenyl groups are usually introduced to improve the refractive index of a silicone material used in LED packaging[11–14]. At the same time, as a rigid group, the content of phenyl will also affect the hardness of the material.
Fan et al.[15] synthesized a hydrogen-containing cross-linker with dihydroxydiphenylsilane and MMH with the catalyst of HCl. After curing with vinyl basic polymer, a silicone material with light transmittance of 86.6% (at 450 nm), a refractive index of 1.581 (at 589 nm), and hardness of 48 shore D was obtained. However, the preparation of the material involves relatively harsh conditions (140℃ under vacuum condition) and the complex synthesis route, which largely restrict its application scope.
Yang et al. [16] synthesized a hydrogen-containing cross-linker with a high refractive index (~ 1.53 at 589 nm) and high transmittance with Karstedt’s catalyst. After it was cured with vinyl base polymer, a silicone material with 92 shore A and tensile strength of 3.8 MPa was obtained, but its transmittance was too low and negatively affected the light extraction efficiency of the prepared LED.
Bae et al.[17] synthesized a linear hydrogen-containing cross-linker through non-hydrolytic sol–gel condensation. After it was cured with vinyl silicone resin, a high-performance LED encapsulant with high transmittance (~ 89.2% at 450 nm) and a refractive index (1.579 at 633 nm) was obtained. However, methyl diethoxysilane used in the synthesis was expensive.
Commercially available hydrogen-containing cross-linkers have a high hydrogen content of about 0.38wt% and a refractive index of about 1.50. Hydrogen-containing cross-linkers with a higher refractive index, a higher hydrogen content, and excellent comprehensive properties were seldom reported.
In previous work[18], we reported a hydrogen-containing methyl-phenyl silicone resin with a high refractive index (~ 1.48 at 633 nm). When it was mixed with vinyl base polymer for curing, the crosslinking density of the products was greatly improved and the hardness reached 86 shore D. However, because of the difference in the curing rate in polymer networks, the curing rate of products inevitably showed the non-uniform crosslinking phenomenon[19]. Due to the network structure formed by the T-link of phenyltrimethoxysilane and a high phenyl content, the stiffness of the products was further increased and a large internal stress was generated in the curing process. These reduce the tensile strength of the product and make it easy to break during the curing process
In this study, in order to replace reticulated silicone resin, we redesigned and synthesized a new linear hydrogen cross-linker to solve the aforementioned problems related to encapsulation. The synthesis process generated no waste water and was simple. First, a linear hydroxy-terminated di-phenyl silicone oil (HTDPSO) was formed by non-hydrolytic sol–gel condensation between diphenyl silanediol and diphenyldimethoxysilane. Then, the obtained hydroxy-terminated phenyl silicone oil reacted with tetramethylcyclotetrasiloxane to form a long-chain linear hydrogen-containing cross-linker, which could realize high condensation and reduce the internal stress during curing. In addition, the process retained the advantage of the hydrogen-containing silicone oil: controllable hydrogen content. After curing, the product showed good optical properties, high reliability, greatly improved tensile strength, and high hardness of 92 shore D, which was much higher than that of reported LED packaging materials.