Ceramic Substrate Metal Reflection Film for LED Heat and Light Management
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Solution Overview
Problem
Conventional light emitting devices using ceramic substrates face a trade-off between heat radiation and optical reflectance, as reducing the substrate thickness improves heat radiation but decreases reflectance, and increasing thickness enhances reflectance but compromises heat radiation.
Innovation Solution
A light emitting device with a metal reflection film on the non-mounting surface of a ceramic substrate, which reflects light transmitted through the substrate, allowing for thinner substrates with improved heat radiation while maintaining high reflectance, and optimizing surface roughness and thickness within specific ranges to prevent fragility and enhance light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the thickness of ceramic substrate is reduced, then heat radiation is improved, but optical reflectance decreases
Solution Approach 1:
The invention divides the substrate system into two functional layers: a thin ceramic substrate for heat dissipation and a separate metal reflection film for optical reflection. This segmentation allows each layer to optimize its specific function without compromising the other, resolving the contradiction between heat radiation and optical reflectance.
Solution Approach 2:
The invention creates a composite structure combining ceramic substrate and metal reflection film. The ceramic substrate provides thermal management properties while the metal film provides optical reflection properties, achieving both heat radiation improvement and high reflectance simultaneously through material composition rather than relying on a single material's inherent properties.
2Illumination intensity
If the thickness of ceramic substrate is increased, then optical reflectance is improved, but heat radiation decreases
Solution Approach 1:
The invention separates the optical reflection function from the heat dissipation function by placing a dedicated metal reflection film on the back surface of the ceramic substrate. This allows the ceramic substrate to be optimized for heat radiation (thin design) while the metal film provides the necessary optical reflectance, eliminating the need to increase substrate thickness for reflection purposes.
Solution Approach 2:
The metal reflection film acts as an intermediary layer that provides the optical reflection function that the thin ceramic substrate cannot provide on its own. This intermediary element enables the system to achieve high reflectance without compromising heat radiation, as the metal film handles the optical function while the ceramic substrate handles the thermal function.
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 enhances both heat radiation and reflectance, achieving higher illuminance and improved light extraction efficiency while preventing substrate fragility, by using a metal reflection film on the ceramic substrate's non-mounting surface and controlling surface roughness and thickness.
Implementation Method 1
a metal reflection film, formed on the non-mounting surface, for reflecting light from the light emitting element transmitted through the ceramic substrate
Implementation Method 2
the ceramic substrate has lower heat conduction than a metal substrate. In order to efficiently dissipate heat, thickness of ceramic substrate must be reduced
Data Source
AI summary
A light emitting device includes a light emitting element, a ceramic substrate including a mounting surface on which the light emitting element is mounted, and a non-mounting surface opposite to the mounting surface and on which the light emitting element is not mounted, and a metal reflection film formed on the non-mounting surface. The metal reflection film reflects light from light emitting element that has passed through the ceramic substrate.