saabluster,
Thanks for the reply. Yup, I guess I didn't read enough of your past posts before posting my questions.
I was wondering why you must remove the dome or else the re-encapsulation will not work. I thought that the optical grade silicone gel you have would have a similar index of refraction as the silicone domes that is over top the K2, Rebel, and the XP-line. Is it a matter of adhesion (so if bumped, air bubbles causing internal reflections would appear)? I was hoping for non-DEFT applications, the apparent die size (like of the XP-G) could be shrunken to work better with smaller reflectors (with only a small decrease in overall output). I was hoping for an emitter that would yield similar results as your oil and water experiments, but without the potential for leakage. Leaky flashlights cause me to get funny looks from non-flashaholics (I use buttered grits as fuel lol).
If the silicone would not work well in contact with with the original silicone gel, could another optically clear and thermally stable material be placed between the original dome and the added silicone gel? I was thinking about something with similar properties to the "binder gel" that sits between the phosphor impregnated silicone and the glass dome of the XR-E, like oil or some other high boiling temperature liquid or gel. I understand what you are doing. I see why it would be easier to remove the dome to guarantee a smaller apparent die size (and why the XR-E is favorable for removal of the dome). I worked on the XR-E as deep as the gooey binder gel above the die's phosphor layer. I did not want to strip the rest of the gel all the way to the phosphor layer in case I would break a bond wire (plus I had no need to go further in my test).
So, I guess that I am not asking you to try this (I got overly excited before). However, is what I am asking even possible?
Oh, and could you tell us where you got your optical grade silicone gel? I would eventually like to invest in some of the gel to try the same. It is awesome to see a fellow nerd use the stuff to make a standard emitter work better in their application. Thanks.
-Tony