materials and solutions for led industry ...dow corning on led market: lighting the way to advanced...

MATERIALS AND SOLUTIONS

FOR LED INDUSTRY

Customer Presentation

www.ellsworth.com

PART 1

Dow Corning and Silicone

Content of Part 1:

• Dow Corning Corporation• Electronics in Dow Corning Today• Dow Corning Electronics Value Chain• What is Silicone?

2008年5月28日星期三9时27分27秒

Presentation Name.ppt

You may know Dow Corning as a global silicone provider

www.ellsworth.com

OUR VISION:We are innovative leaders unleashing the powers of silicon to benefit everyone, everywhere

The silicone technology pioneer…- A joint venture of The Dow Chemical Company and Corning, Inc.- Organized to explore the

potential of the silicon atom

Serving customers’ diverse needs…• Automotive• Beauty & Personal Care• Chemical Manufacturing• Compound Semiconductor• Construction• Electronics • Food & Beverage• Healthcare • Household & Cleaning• Imaging• Industrial Lubrication• Paints and Inks • Power and Utility• Pressure Sensitive• Rubber Fabrication• Textile, Leather & Nonwoven• Services

Electronics in Dow Corning Today is….

• Dow Corning Electronics is a globally integrated provider of materials, application technology and services. We are dedicated to becoming the top-rated supplier at each of our customers in the electronics value chain – from semiconductor fabrication, to device packaging and complete module and system assembly

Separate Industry: Electronics and Advanced Technology (E&AT)

Our goal:

Silicones are inorganic compounds with inherently unique properties.

In electronics applications, silicones are especially designed and formulated to function as:

• Durable dielectric insulation

• Stress-relieving and vibration absorbers over a very wide temperature/humidity range

• Barriers against environmental contaminations

• Thermal management materials

What is Silicone?

Silicones are inorganic compounds with inherently unique properties.

Silicones = Proven Reliability !

Dow Corning Product Family

Encapsulantsand Potting

Adhesive and Sealants

Thermally

conductive

Conformal coating Gels

Elastomers

PART 2

Dow Corning Silicone materials for LED Applications

Content of Part 2:

What is LED?Dow Corning on LED MarketLED Value Chain

What is LED?Since their inception in the early ‘60’s, light emitting diodes (LEDs) have gained widespread use and now can be found nearly everywhere.The devices are created by depositing two thin layers of materials onto a substrate, one with an excess of electrons and the other having “holes”and needing electrons to achieve a more stable state.

When a potential is applied across the device, the electrons and holes move in the opposite directions. This causes light to be emitted with a wavelength and color determined by the energy released when the electrons and holes combine.

History of LED

LED Trends…Today, special deposition techniques have made possible LEDswith much higher brightness (HBLEDs) than traditional devices.This opens up many new applications such as backlighting for displays, automotive lighting and new consumer products like flash for camera phones or compact projectors.

Goals for these new HBLEDs are to have them:

• Be Brighter • Last Longer • Cost Less • Be Compatible with Lead-free Processing

Dow Corning on LED market:Lighting the Way to advanced materials and solutions

Lighting the Way to advanced materials•New global product group focused on the LED market.•Expanded family of optoelectronic gels, elastomers and resins for high-brightness LEDs.•Compared with organics, silicones offer profitable benefits•Field-proven ranges of materials for LED integration and final assemblyand solutions •Global product, application and sales staff•Global distribution network•Process and equipment expertise•Analytical, environment and physical testing•Globally integrated supply chain•On-site education and training about silicones

Dow Corning is your reliable materials and solution provider at every step of LED value chain!

LED Protection &Assembly:• Gels• Encapsulants• Adhesives• Conformal Coating

LED Thermal Management: Thermal Interface Materials •Wet Dispensed•Fabricated

LED Packaging: •NRI and HRI Encapsulants•HRI Silicone Lens Resin

Advanced silicone technology fro LED applications:

Silicone Opportunities in LED

XXXXXXXXXXXXXXFTF Cure Adhesive

XXGel

XXXXXXXXXXXPottant

XXXXXXXXXXXXXConformal Coating

XXXXXXXHeat Cure Adhesive

LCD Back Lighting

Unit

Signage/ Interior/ Medical/ Portable

Architecture/ Entertainment

/ City Beautification

Outdoor Display

Home Appliance

Automotive/ Signaling/ Roadway

PART 3

LED Protection And Assembly

Content of Part 3:

1. Why Dow Corning for LED protection and assembly?2. Dow Corning Silicone Products for LED protection and assembly• Gels & Encapsulants• Adhesives• Conformal Coating

1. Why Dow Corning for LED protection and assembly?

LED Protection &Assembly:• Gels & Encapsulants• Adhesives & Sealants• Conformal Coating

Gel & Elastomers

• Silicone elastomer helps protect electronic components and circuits from moisture and contamination; relieves thermal and mechanical stress.

• Dow Corning offers a line of standard gels, a line of low-temperature gels for applications requiring low-temperature performance, and a line of specialty gels for applications requiring low extractables, ultra-violet (UV) cure, or resistance to solvents and fuels.

• Liquid mixture cures to a flexible elastomer, which is suited for the protection of electrical/electronic assemblies. Select materials have been classified by Underwriters Laboratories.

• Standard silicone encapsulants require a surface treatment with a primer while primerless silicone encapsulants require only good cleaning.

Their major job is to protect electronic assemblies and components from adverse environments by:

• Functioning as dielectric insulation • Protecting the circuit from moisture and other contaminants • Relieving mechanical and thermal stress on components

Gel & Elastomers

Encapsulants: Some Common ApplicationsTypical applications:LED outdoor/indoor panels (Stadium…)LED Traffic Lights

Need: to protect the assembly of LED’s and circuit board against humidity and environmental stress

Product:Dow Corning® 3-4207 tough gel (selected because of good

adhesion and fast room temperature cure).Dow Corning® SE 1816 CV or Dow Corning® SE 1817 CV

(selected because of self-priming capability)Dow Corning EE-1840 (selected because of black color and room temperature cure)

Adhesives & Sealants

Adhesive: Adhesive: Substance capable of holding materials together by surface attachmentSealant: Sealant: Material applied to a joint or gap to form a seal against gas or liquid entry

Sealing, Bonding, and AdheringDow Corning offers a variety of noncorrosive silicone products for electronic sealing, bonding and adhering applications. These adhesives generally fall into three cure types:

• The first group are moisture cures, generally meant for room-temperature processing. • The second type (condensation cure) offers rapid room-temperature and deep-section curing. • The third type is heat cure for rapid processing. All convert to durable, relatively low stress

elastomers. Most will develop good, primerless adhesion to a variety of common substrates including ceramics, reactive metals and filled plastics.

Noncorrosive silicone products for electronic sealing, bonding and adhering applications.

• Resistant to weathering• Stable at high temperatures• Flexible at low temperatures• Excellent electrical properties

Adhesive/Sealants

Adhesives & Sealants: Some common applications

Case: Large outdoor video display panels used in stadiums, exhibitions etc... High intensity LED’s (Blue, green and red) are used as base pixels for live video displays.

Need: Assembly of PCB into plastic frame

Product: Dow Corning® 744 adhesive/sealant (excellent adhesion on plastics)

Typical applications:• Architectural lighting• Automobile interior and

exterior lighting• Indicators, switchers,

keypads• LCD backlighting• Displays• Mobile device light

sources• Projector light sources• Traffic lights and

guidance

Conformal Coating

Dow Corning's line of conformal coatings includes three basic families: • RTV Elastomeric Coatings, the newest of these, are designed to provide fast to very fast

room temperature curing in a soft, stress-relieving material. • The next group, the RTV Elastoplastic Coatings, is either traditional or ozone-safe solvent-

based coatings that provide good abrasion resistance with the expected good board protection.

• The third group, the Solventless Heat Cure Coatings, is fast heat-curing one-part coatings that again combine excellent protection in a soft, stress-relieving material.

• All conformal coatings contain a UV indicator enabling black light visualization of the coating.

Silicone Conformal coatings protect circuit from moisture and contaminants, to prevent:•Short circuits•Corrosion of conductors and solder joints•Dendritic growth and the electromigration of metal between conductors•Protection from abrasion and solvents•Elastomeric coatings provide stress relief

Conformal Coatings

NOTE: Please check with your local Dow Corning office for a full product range and availability in your area.

Conformal Coating: Some Common Applications

• Case: Driver circuit for LED-based automotive lighting • Need: Protection from humidity• Product: Dow Corning® Q1-4010

PART 4

LED Thermal Management

Content of Part 4:

1. Why Dow Corning for LED Thermal Management?2. Dow Corning Solution for Thermal Management• Thermal Interface Materials – Wet dispensed• Thermal Interface Materials – Fabricated


LED Thermal Management:

Thermally Conductive Materials:

• Wet dispensed• Fabricated

Thermally Conductive Materials

When markets demand smaller, faster, less expensive electronic devices and assemblies, you respond. But smaller components, tighter lead spacing and increased operating frequencies result in higher temperatures that can reduce performance and reliability.Heat is the enemy of performance. To win over this enemy Dow Corning can offer you:

• Thermal Interface Materials - Wet Dispensed• Thermal Interface Materials - Fabricated

Functions of Thermally Conductive materials:

•Carry heat transfer AWAY from components to the environment•(Electrical insulation) between components and casing•Flexible fixation

Thermal Interface Materials - Wet Dispensed

Adhesives– One or two-part silicone elastomer– Nonflowable and flowable options; cures to flexible elastomer– Fast thermal cure, or RTV cure available; resists humidity and other harsh environments;

good dielectric properties; self-priming adhesion; low stress; noncorrosiveEncapsulants

– Two-part silicone elastomer– Flowable liquid; cures to flexible elastomer– Constant cure rate, regardless of sectional thickness or degree of confinement; no post-cure

requiredGels

– Two-part silicone gel– Low to moderate viscosity; cures to gel like material– Long working times, fast thermal cure; resists humidity and other harsh environments; good

dielectric properties; self-priming adhesion; low stress; non-corrosiveCompounds

– Non-curing, thermally conductive silicone paste .

– High thermal conductivity; low bleed; high-temperature stability

Dispensable, printable and curable materials effective as heat transfer media

Thermal Interface Materials - Wet Dispensed

Thermal Interface Materials - Wet Dispensed : Some Common Applications

• Case: Lighting (Automotive)• Need: Transfer heat from a flexboard carrying power

LEDs to series of individual heatsinks• Product: Dow Corning® SE4486 RTV adhesive

Thermal Interface Materials - Fabricated

Dow Corning offers Thin Thermal Interfacematerials and Gap Filler Thermal Interfacematerials for use on irregular surfaces.

Cold applied pre-cured, easy to die cut, highly compressible from both sides to improve thermal resistance.

Thermal Interface Materials - Fabricated

Thermal Interface Materials – Fabricated: Some Common Applications

Case : Arcade machinesNeed: Transfer heat from a band of low power LEDs to

the heatsink for arcade machines Product: Dow Corning® TP-1500 Thermal Pads

PART 5

LED Packaging

Content of Part 5:

1. Why using Dow Corning Silicones for LED Packaging?2. Dow Corning Materials for LED Packaging

• Optical Encapsulants : Gel, Elastomer and Resin• Lens Molding :Elastomer and Resin


LED Packaging:

• Optical gels, encapsulants & resins

Why using Dow Corning Silicones for LED packaging ?

Reliable dispense and molding processesWide range of viscosities available

Efficient automated assembly processDispensed or molded by a variety of techniques

Well-suited for near IR, visible, or UV wavelength applications

Excellent optical properties (high light transmittance)

Minimized corrosion potentialLow ionic content (typically ionic levels <1 ppm)

Improved device reliability because of delaminationresistance

Excellent adhesion to a wide variety of materials

Design flexibility to absorb stress within the packageVariable modulus (typically less than 1 MPa)

Packages can be designed to conform to industry reliability standards

Very low moisture uptake

Enables packages to pass common industry reliability and lead-free reflow temperatures

Excellent thermal stability (as low as -45 to >260ºC)

BenefitFeature

Optical EncapsulantsEncapsulants: Gel, Elastomer and Resin

Dow Corning provides both High RI and Normal RI OE series silicone encapsulants, which have outstanding light transmittance across the application wavelengths of LEDs.

These encapsulants provide excellent stress relief, moisture protection and UV resistance for LED chip sealing and protection.

• Physical Form: Low to medium viscosity liquid; cures to a flexible gel or elastomer.

• Special Properties: Transparent with refractive index range of 1.41 to 1.53.

• Potential Use: Protection of LED devices

Finding your way between High RI and Normal RI

OE-6550

EG-6301OE-6336

Hard Elastomer

Shore A>50

OE-6665OE-6630OE-6635

JCR 6175OE-6520

OE-6450High RIRI>1.5

JCR 6122JCR 6110OE-6250

Hipec Q1-4939

Normal RIRI 1.4

ResinShore D>30

Soft Elastomer

Shore A<50

GelShore A<10

High RI Optical Encapsulants

Normal RI Optical Encapsulants


Why using Silicone Encapsulants with LED?

How to use Silicone Encapsulants?Mixing – 1:1/Part A:Part B• supplied in two parts that require lot matching. • The 1:1 mix ratio, by weight or volume, simplifies the proportioning process. • When thoroughly blended, the Part A and B liquid mixture should have a uniform appearance. The presence of

light-cloudy streaks indicates inadequate mixing and will result in incomplete cure.• Due to the fast-curing characteristics of some encapsulants included in this datasheet, automated mix and

dispense equipment should be utilized. In applications sensitive to air entrapment, de-airing with 28 to 30 inches Hg vacuum is required

Mixing – 1:N/Part A:Part B• supplied in two parts as lot-matched • Part A and Part B that are mixed in a ratio of 1 part Part A to specified parts Part B, by weight.• After thoroughly mixing Part A and Part B, agitate gently to reduce the amount of air introduced. Allowing the

mixture to set for 30 minutes before pouring may be adequate for removal of the air introduced during mixing. If air bubbles are still present, vacuum deairing may be required. De-air in a container with at least four times the liquid volume to allow for expansion of material. Air entrapped in the mixture can be removed by using a vacuum of 28 to 30 inches Hg. Continue the vacuum until the liquid expands

• and settles to its original volume and bubbling subsides. This may take 15 minutes to 2 hours depending on the amount of air introduced during stirring.

• For best curing results, glassware and glass or metal stirring implements should be used. Mix with a smooth action that does not introduce excess air.

How to use Silicone Encapsulants?PREPARING SURFACES• For best results, the primer should be applied in a very thin, uniform coating and then wiped off after

application• After application, it should be thoroughly air dried prior to application of the silicone elastomer• See the Primer Selection Guide for the correct primer to use with a given product.

USEFUL TEMPERATURE RANGES• should be operational over a temperature range of -45 to 200°C (-49 to 392°F) for long periods of time• For low-temperature performance, thermal cycling to conditions such as -55°C (-67°F) may be possible, • However, at both the low and high temperature ends of the spectrum, behavior of the materials and

performance in particular applications can become more complex and require additional considerations.

STORAGE AND SHELF LIFE• For best results, Dow Corning silicone encapsulants should be stored at or below 25°C (77°F)• Any special storage and handling instructions will be printed on the product containers

Lens MoldingLens Molding: Elastomer and Resin• Dow Corning provides the high RI resin material needed for optical

lens fabrication. These products are designed with excellent injection and compress molding characteristics.

FeaturesShore D Range HardnessHigh optical transparencyExcellent UV, temperature and moisture stability

Applications:Discrete Lenses for LEDsOn-chip molded lenses (overmolding)Light guides, light pipes

Lens Molding


Lens Molding: Methods • Cavity Molding (Casting)

Low cost of ownership, Low material loss

• Compression Molding (Overmolding)Low running cost – Substrate level processMaterial options : high RI OE-66XX resins series

• Injection moldingHigh productivity, complex shape manufacture

Examples of Molded Parts

PART 6

Applications for Silicone in LED's

Content of Part 6:• LED: Key Market Drivers• LED: Lighting Market Value Chain• Silicone Opportunities in LED• Dow Corning Unique Selling Proposal for LED market• Dow Corning Selling Tools• Additional information


Applications for Silicone in LED's

LED: Key Market Drivers• Outdoor Display: LED Assembly moving to SMD, Customization of matte

black finish color – every company has different spec’s• Outdoor signs: starting to explore different products from matte

encapsulation material, thermal gap material, to conformal coating material. Lighter materials as HD digital signs strives for module weight reduction

• Automotive: driven by issues of styling and customer appeal, although lifetime and power efficiency are also important considerations

• Require dedicated heat conduction path, separate from electrical path of LED packages. Excellent thermal performance matches demands of high drive currents – TIM opportunities

• System Integration: LED manufacturers to consider assembling thermal, optical, power supplies and control systems – it provides value propositions to LED manufacturer

LED: Lighting Market Value ChainOwner

Architect

Engineer

General Contractor

Lighting Designer

Electrical Contractor

Distributor

Luminaire ManufacturerAgent/Rep.

SpecificationLevel

PurchasingLevel

LED Manufacturer

Dow Corning Unique Selling Proposal for LED market

Dow Corning is the answer to your LED’s needs from high performance optical materials, potting and

thermal management solutions to a highly integrated molding equipment and application process capability

complemented with the global research and development experts.

materials and solutions for led industry ...dow corning on led market: lighting the way to advanced...

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