Ceramic LED Mounting Substrate With Sloped Reflective Base
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Solution Overview
Problem
Conventional light-emitting element mounting substrates face challenges in minimizing reflected light incidence on the light-emitting surface, leading to reduced output and shortened element lifespan due to inefficient heat dissipation and directional light control.
Innovation Solution
A substrate with a ceramic base and sloping surface configuration that reflects emitted light at a controlled angle, integrated with heat-efficient materials like aluminum nitride, and featuring electrical conductors for improved heat transfer and reduced heat resistance, along with recessed parts and dam structures for stable mounting and positioning accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional metal base with ceramic sub-mount is used for mounting light-emitting elements, then heat dissipation is improved, but reflected light may readily incident on the light-emitting surface causing reduced output and shortened lifespan
Solution Approach 1:
The base is designed with an asymmetric sloping surface configuration where the mounting surface is inclined at a specific angle (e.g., 30-60 degrees) relative to the light emission direction. This asymmetric geometry causes reflected light to diverge away from the light-emitting surface, preventing feedback into the light-emitting element while maintaining effective heat dissipation through the base structure.
Solution Approach 2:
The invention transitions from a conventional flat, planar mounting structure to a three-dimensional sloping surface configuration. By introducing angular dimensionality to the base mounting surface, the patent creates spatial separation between the light emission path and reflected light paths, effectively directing reflections away from the light-emitting element while preserving thermal conduction efficiency.
2Ease of manufacture
If a flat mounting surface is used on the substrate, then manufacturing is simplified, but reflected light readily returns to the light-emitting surface reducing output
Solution Approach 1:
The mounting surface is designed with a specific asymmetric slope angle (e.g., 30-60 degrees) relative to the light emission axis. This controlled asymmetry optimizes light reflection geometry to prevent feedback into the light-emitting element, thereby maintaining high light output efficiency while remaining compatible with standard ceramic sintering and machining processes.
Solution Approach 2:
The patent optimizes specific geometric parameters of the sloping surface, including the inclination angle (e.g., 30-60 degrees), slope length, and mounting surface area ratios. These parameter optimizations ensure effective light reflection control while maintaining manufacturability through conventional ceramic processing techniques such as tape casting, sintering, and precision cutting.
3Stability of the object's composition
If the top surface of the base is made parallel to the front surface of the substrate, then structural alignment is simplified, but heat resistance increases and heat dissipation efficiency decreases
Solution Approach 1:
The base mounting surface is configured with a specific angular orientation (e.g., 30-60 degrees) relative to the substrate front surface, creating a three-dimensional geometric relationship rather than a simple parallel alignment. This angular configuration maintains stable structural attachment through the sloping geometry while optimizing thermal conduction pathways from the light-emitting element mounting position to the substrate heat dissipation structures.
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 decreases reflected light incidence, enhances heat dissipation, and extends the lifespan of light-emitting elements while maintaining high output and directional control, allowing for efficient light emission and improved device performance.
Implementation Method 1
a base (3) that protrudes from a front surface (1a) of the substrate (1) and has a sloping surface (3a) with respect to the front surface (1a) of the substrate (1)
Implementation Method 2
The substrate and the base are integrally formed of a ceramic having high heat-releasing properties
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A substrate for mounting a light-emitting element includes a substrate 1 with a plate shape and a base 3 that protrudes from a front surface 1a of the substrate 1, wherein the base 3 has a mounting part 3aa for mounting a light-emitting element 5 on a top surface 3a thereof and composes a sloping surface 3a that slopes with respect to the front surface 1a and the substrate 1 and the base 3 are integrally formed of a ceramic. The substrate 1 has two opposing end surfaces 1b, 1c and when a part with a lower height from the front surface 1a on the sloping surface 3a is provided as a lower position part 1L, the lower position part 1L is arranged along one of the two end surfaces 1b, 1c. An array substrate is provided wherein a plurality of substrates for mounting a light-emitting element as described above are joined. A light-emitting device has the light-emitting element 5 on the mounting part 3aa of a substrate for mounting a light-emitting element as described above or the mounting part 3aa of an array substrate as described above.