Wavelength Conversion Layer Slits for Dense LED Element Spacing
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Solution Overview
Problem
In light-emitting devices, the decrease in separation distance between light-emitting elements can cause the liquid adhesive to run into the spaces between them, inhibiting the proper placement of a light-reflecting member, which may lead to deteriorated light-emitting characteristics.
Innovation Solution
A method involving a light-transmissive sheet with a light diffusion layer and a wavelength conversion layer, where the wavelength conversion layer is heat-treated to increase its hardness, and slits are formed to create element arrangement regions for direct contact with light-emitting elements, followed by a covering member placement between elements and in the slits to enhance light-emitting characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the separation distance between light-emitting elements is decreased, then the light-emitting device can achieve higher pixel density and better resolution, but the liquid adhesive may run into the space between adjacent light-emitting elements, inhibiting the light-reflecting member from being properly disposed and deteriorating light-emitting characteristics
Solution Approach 1:
The patent divides the wavelength conversion layer into multiple element arrangement regions separated by slits. This segmentation prevents adhesive from spreading between adjacent light-emitting elements while maintaining close spacing for high pixel density. The slits act as physical barriers that segment the adhesive flow paths.
Solution Approach 2:
The patent performs preliminary actions by forming slits in the wavelength conversion layer before disposing the light-emitting elements. This preliminary structuring of the layer creates predetermined adhesive containment regions, ensuring that when adhesive is applied later, it cannot run into adjacent element spaces and interfere with light-reflecting member placement.
2Ease of operation
If liquid adhesive is used to dispose light-emitting elements on the wavelength conversion layer, then the elements can be easily positioned, but the adhesive may run into spaces between elements and prevent proper placement of light-reflecting members
Solution Approach 1:
The wavelength conversion layer is segmented into discrete element arrangement regions by forming slits between them. This segmentation contains the liquid adhesive within each region, allowing easy positioning of light-emitting elements using adhesive while preventing the adhesive from migrating to adjacent regions where it would block light-reflecting member placement.
Solution Approach 2:
The patent applies local quality by creating regions with different properties: areas under light-emitting elements have adhesive for positioning, while areas between elements (the slits) have no adhesive to allow light-reflecting member placement. This localized differentiation of adhesive presence solves the contradiction between ease of positioning and reliability of light-emitting characteristics.
3Manufacturing precision
If slits are formed to prevent adhesive running, then adhesive containment is improved, but the structural integrity of the wavelength conversion layer may be compromised
Solution Approach 1:
The patent applies partial action by forming slits that extend only to a controlled depth within the wavelength conversion layer, not completely through it. This partial penetration is sufficient to contain adhesive while maintaining the overall structural integrity of the layer, avoiding the weakness that would result from complete through-slits.
Solution Approach 2:
The wavelength conversion layer acts as a flexible matrix that can accommodate the slits without compromising overall integrity. The layer's material properties allow it to maintain strength while containing the adhesive in designated regions, balancing structural requirements with adhesive containment needs.
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 approach improves light-emitting characteristics by preventing adhesive interference and ensuring proper placement of the covering member, resulting in enhanced light extraction efficiency and contrast.
Implementation Method 1
performing a first heat treatment on the wavelength conversion layer under a first condition to increase a hardness of the wavelength conversion layer
Implementation Method 2
performing a second heat treatment on the wavelength conversion layer under a second condition to cure the wavelength conversion layer
Data Source
AI summary
A method for manufacturing a light-emitting device includes providing a light-transmissive sheet that includes a light diffusion layer including a first resin portion and a light diffusion substance and a wavelength conversion layer disposed on the light diffusion layer and including a second resin portion in a stage B state and a wavelength conversion substance; performing a first heat treatment on the wavelength conversion layer; dividing an upper surface of the wavelength conversion layer into element arrangement regions by forming a first slit extending from the upper surface of the wavelength conversion layer, passing an interface between the wavelength conversion layer and the light diffusion layer, and reaching the light diffusion layer; disposing a light-emitting element in each of the element arrangement regions; performing a second heat treatment on the wavelength conversion layer; and disposing a covering member between the light-emitting elements and in the first slit.