Conversion Element Reflective Sidewalls for Low Optical Crosstalk
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Solution Overview
Problem
Current methods for producing conversion elements that convert primary radiation into secondary radiation of longer wavelength are costly and inefficient, particularly in creating optoelectronic semiconductor components with effective wavelength conversion and minimized side emissions.
Innovation Solution
A method involving a frame with openings filled with a sacrificial layer, covered by a thin metallic reflective layer, and infused with a conversion material that uses photolithography and chemical etching to create a conversion element with a metallic reflective layer surrounding the side surfaces, minimizing side emissions and enabling efficient wavelength conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to produce conversion elements, then manufacturing cost is high, but production efficiency and cost-effectiveness deteriorate
Solution Approach 1:
The conversion element is divided into distinct functional layers: a substrate, a conversion material layer containing phosphor particles, and a reflective layer. This segmentation allows each layer to be optimized and manufactured separately using standard semiconductor processes, reducing overall manufacturing cost while improving production efficiency through modular fabrication.
Solution Approach 2:
The patent changes the physical and chemical parameters of the conversion material layer by controlling particle size distribution, concentration of phosphor particles, and thickness of the layer. These parameter optimizations enable efficient wavelength conversion while using standard semiconductor manufacturing techniques, thereby reducing costs and improving productivity simultaneously.
2Reliability
If conversion material is applied to convert primary radiation, then wavelength conversion efficiency is improved, but side emissions and optical crosstalk increase
Solution Approach 1:
The reflective layer acts as an intermediary between the conversion material layer and the underlying substrate. It reflects stray light and primary radiation that would otherwise cause optical crosstalk back into the conversion layer, thereby improving wavelength conversion efficiency while minimizing harmful side emissions. This mediator layer effectively manages light pathways to eliminate unwanted radiation.
3Volume of moving object
If conversion element dimensions are reduced, then integration density is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces traditional mechanical assembly methods with semiconductor fabrication processes such as sputtering for the reflective layer and spin coating or printing for the conversion material layer. These process-based approaches enable precise control of thin film thicknesses and material deposition at micrometer and nanometer scales, allowing miniaturization without compromising manufacturing precision.
Solution Approach 2:
The conversion element utilizes thin film structures for both the reflective layer and the conversion material layer. These thin films can be precisely controlled in thickness during deposition processes, enabling miniaturization of the overall device while maintaining manufacturing precision through established semiconductor thin film fabrication techniques.
4Reliability
If reflective layer is added to minimize side emissions, then optical performance is improved, but device complexity increases
Solution Approach 1:
The reflective layer serves multiple functions simultaneously: it reflects primary radiation back into the conversion layer to improve conversion efficiency, it acts as a barrier layer to prevent diffusion of conversion material into the substrate, and it provides a defined interface for light extraction. This multi-functionality improves optical performance while avoiding the need for additional separate structural elements, thereby limiting the increase in device complexity.
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 method produces cost-effective optoelectronic semiconductor components with improved light coupling and reduced optical crosstalk, allowing for smaller dimensions and increased efficiency in radiation conversion and emission.
Implementation Method 1
The material removal can be produced by chemical etching, for example
Implementation Method 2
The conversion element is configured to convert primary radiation into secondary radiation of longer wavelength, for example
Implementation Method 3
applying a reflective layer to the sacrificial layer
Data Source
AI summary
The invention relates to a method for producing a conversion element having the following steps: providing a frame having an opening; applying a sacrificial layer at least to a side surface of the at least one opening; applying a reflective layer to the sacrificial layer; introducing a conversion material into the at least one opening, the conversion material covering the reflective layer; and removing the sacrificial layer and the frame.