Light Reflective Member Amorphous Metal Layer Ag Thickness
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Solution Overview
Problem
The high cost of silver (Ag) in light emitting devices due to its high optical reflectance properties is mitigated by forming a thin Ag layer, which results in reduced optical reflectance and increased material costs, necessitating a solution that maintains reflectance while minimizing Ag usage.
Innovation Solution
A light emitting device configuration that includes a base metal, an amorphous layer made of amorphous metal, and an Ag-containing layer, where the amorphous layer reduces the influence of the base metal's crystal structure on the Ag layer, allowing for high optical reflectance even with a thinner Ag layer, thus optimizing light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a thin Ag layer is formed to reduce cost, then material cost decreases, but optical reflectance is reduced
Solution Approach 1:
The patent uses a composite structure consisting of a base metal layer, an amorphous metal layer, and an Ag-containing layer. This composite material approach allows the thin Ag layer (reducing cost) to work synergistically with the amorphous metal layer to achieve high optical reflectance, resolving the contradiction between material quantity and optical performance.
Solution Approach 2:
The patent changes the physical state parameter of the metal layer from crystalline to amorphous. The amorphous metal layer provides superior optical reflectance properties compared to crystalline structures, enabling the system to maintain high reflectance with reduced Ag content, thus resolving the contradiction between cost and optical performance.
2Ease of manufacture
If Ag layer thickness is reduced, then manufacturing cost decreases, but light extraction efficiency deteriorates
Solution Approach 1:
The composite structure of base metal + amorphous metal + Ag-containing layer creates a synergistic effect where the amorphous metal layer compensates for the reduced Ag thickness, maintaining high light extraction efficiency while reducing material cost.
Solution Approach 2:
The amorphous metal layer acts as an intermediary between the base metal and the Ag-containing layer, enhancing the overall optical performance and allowing the thin Ag layer to achieve the desired light extraction efficiency without compromising productivity.
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
This configuration achieves high optical reflectance and light extraction efficiency while reducing material costs by using a thinner Ag layer, enhancing the brightness and reliability of the light emitting device.
Implementation Method 1
an amorphous layer provided over the base metal and made of an amorphous metal
Implementation Method 2
silver (Ag), which has a high reflectance for light emitted from the light emitting elements
Implementation Method 3
forming an amorphous layer made of an amorphous metal on the base metal by plating, and forming an Ag-containing layer on the amorphous layer by plating
Data Source
AI summary
A light emitting device includes: a light emitting element; and a light reflective member adapted to reflect light emitted from the light emitting element, the light reflective member comprising a base metal made of a crystallized metal, an amorphous layer located over the base metal and made of an amorphous metal, and an Ag-containing layer located over the amorphous layer.