Graphene-Based Light-Emitting Element With Microstructures
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Solution Overview
Problem
Conventional light-emitting diodes (LEDs) face challenges with sapphire substrates due to low thermal conductivity and difficulty in processing, and graphene's non-reactive surface makes it hard to grow microstructures or thin-films effectively.
Innovation Solution
A light-emitting element is created using a carbon layer with graphene, where microstructures are grown upward and a light-emitting structure layer is formed on these microstructures, enabling transfer to various substrates and leveraging graphene's excellent electrical and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sapphire substrate is used for LED manufacturing, then light transmission property and mechanical strength are improved, but thermal conductivity and ease of processing deteriorate
Solution Approach 1:
The patent introduces a carbon layer as an intermediary substrate between the LED structure and the final application. This carbon layer serves as a mediator that enables easier processing and substrate replacement while maintaining the structural integrity and performance benefits of the original sapphire-based LED structure. The carbon layer acts as a transfer medium that facilitates the movement and adaptation of the LED structure to different substrates.
2Illumination intensity
If a sapphire substrate is used for LED manufacturing, then light transmission property is improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent segments the LED structure into separable components: the light-emitting structure grown on carbon layer, and the final substrate. This segmentation allows the light transmission properties to be optimized in the carbon layer and initial growth substrate, while the final substrate can be selected independently for thermal conductivity requirements. The separable structure enables independent optimization of optical and thermal properties in different layers.
3Temperature
If graphene is used as substrate material, then thermal conductivity and electrical conductivity are improved, but ease of growing microstructures deteriorates
Solution Approach 1:
The patent uses a carbon layer as an intermediary that bridges the gap between graphene's excellent thermal conductivity and the need for microstructure growth. The carbon layer provides a surface that is chemically suitable for growing microstructures while maintaining the thermal management benefits of graphene-based materials. This intermediary approach allows combining the thermal advantages of graphene with the manufacturability of traditional substrates.
4Reliability
If graphene is used as substrate material, then electrical conductivity is improved, but difficulty in growing microstructures increases
Solution Approach 1:
The carbon layer serves as a chemical intermediary that provides suitable growth conditions for microstructures while maintaining electrical conductivity. This intermediary layer has different surface chemistry compared to pure graphene, making it more amenable to microstructure growth while preserving the electrical properties needed for LED operation.
5Ease of manufacture
If laser lift-off process is used for vertical type LED manufacturing, then substrate removal is achieved, but device complexity increases
Solution Approach 1:
The patent extracts the substrate removal function from complex laser lift-off processes and replaces it with a simple carbon layer that can be easily removed or transferred. The carbon layer is designed to be separable from the final substrate, allowing for simple removal or transfer of the LED structure without requiring complex laser processing equipment or procedures. This extraction of the substrate removal function simplifies the overall manufacturing process.
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 results in a high-efficiency light-emitting element with improved electrical and optical properties, allowing for heat dissipation and flexibility in substrate selection, enhancing luminous efficiency and reducing contact resistance.
Implementation Method 1
Since graphene has excellent thermal conductivity, it is possible to avoid performance degradation of a light-emitting element due to the heat
Implementation Method 2
Since graphene has excellent electrical conductivity, it is possible to use graphene or graphite as a bottom electrode
Implementation Method 3
growing a plurality of microstructures upward on the carbon layer
Data Source
AI summary
The present invention provides a light-emitting element comprising: a carbon layer comprising a graphene; a plurality of fine structures having grown toward the upper side of the carbon layer; and a light-emitting structure layer formed on the surface of the fine structures.