Light-Emitting Apparatus With Cavity Wavelength Conversion Layer
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Solution Overview
Problem
Conventional light-emitting device packages face increased manufacturing costs and optical quality issues due to the size of the package and leakage of blue light, which is not effectively converted to white light.
Innovation Solution
A light-emitting apparatus with a reflective layer having a cavity that houses a light-emitting device and a wavelength conversion layer, where the wavelength conversion layer exposes the electrode and covers the light-emitting device, ensuring efficient conversion of blue light to white light without the need for a lead frame, thereby reducing manufacturing costs and enhancing optical quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lead frame is used to mount the light-emitting device chip in a package, then the package provides structural support and electrical connection, but the package size increases and manufacturing cost increases
Solution Approach 1:
The patent removes the lead frame from the package structure, extracting the unnecessary component that causes increased size and cost. The light-emitting device chip is mounted directly to the circuit board, eliminating the intermediate lead frame structure while maintaining functional requirements through alternative mounting and connection methods.
2Use of energy by moving object
If blue light is emitted directly without wavelength conversion, then the light-emitting device operates efficiently, but blue light leaks and fails to be converted to white light, degrading optical quality
Solution Approach 1:
The patent introduces a wavelength conversion layer as an intermediary between the blue light-emitting device and the external environment. This layer contains phosphor materials that absorb blue light and convert it to white light, preventing blue light leakage while maintaining the efficiency of the original light-emitting device.
3Ease of manufacture
If the wavelength conversion layer covers the entire cavity, then blue light conversion is maximized, but the electrode is hidden and electrical connection becomes difficult
Solution Approach 1:
The patent applies local quality by making the wavelength conversion layer semi-transparent in specific regions, allowing it to maintain light conversion functionality while permitting light and electrical signals to pass through to the electrode. This localized modification enables both optical and electrical functions to coexist without full coverage obstruction.
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 solution effectively converts blue light to white light, reducing leakage and improving optical quality while minimizing manufacturing costs by eliminating the need for a lead frame and simplifying the packaging process.
Implementation Method 1
a wavelength conversion layer that fills the cavity and covers at least one of a top surface and a side surface of the light-emitting device
Implementation Method 2
a reflective layer including a cavity that penetrates the reflective layer from a top surface to a bottom surface of the reflective layer
Data Source
AI summary
A light-emitting apparatus includes a reflective layer including a cavity that penetrates the reflective layer from a top surface to a bottom surface of the reflective layer; a light-emitting device disposed in the cavity, the light-emitting device including a light-emitting stack and an electrode connected to the light-emitting stack at a bottom surface of the light-emitting stack; and a wavelength conversion layer that fills the cavity and covers a top surface and a side surface of the light-emitting device, wherein the wavelength conversion layer exposes at least a portion of the electrode to an outside.