Component having an integrated converter layer and method for producing a component
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Solution Overview
Problem
Current light-emitting components, such as laser converter units, are complex and costly to manufacture due to numerous processing steps, and light-emitting diodes exhibit efficiency droop at high outputs, making them unsuitable for applications like horticulture and projection, which require efficient and cost-effective light sources.
Innovation Solution
A compact light-emitting component with a semiconductor body and integrated converter layer, where the converter layer is applied monolithically and self-aligned during facet etching, reducing handling steps and enabling efficient conversion of short-wavelength to long-wavelength radiation, and allowing for a cost-effective, high-luminance laser converter unit production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser converter units are used to achieve high efficiency and suitability for projection applications, then the light source becomes suitable for horticulture and projection, but the manufacturing complexity and costs increase due to numerous processing steps and adjustment processes on individual semiconductor chips
Solution Approach 1:
The patent combines the semiconductor chip with the converter layer into a single integrated component. The converter layer is applied directly onto the semiconductor chip surface, merging two previously separate components (laser chip and converter) into one unified structure, thereby reducing the number of handling steps and adjustment processes while maintaining high efficiency and suitability for projection applications
Solution Approach 2:
The converter layer is applied onto the semiconductor chip before final assembly and adjustment. This preliminary action allows the converter to be positioned and integrated in advance, eliminating the need for complex post-assembly adjustments and reducing manufacturing complexity while ensuring proper alignment for high-efficiency operation
2Reliability
If laser converter units are used to achieve high efficiency and suitability for projection applications, then the light source becomes suitable for horticulture and projection, but the manufacturing costs increase due to numerous processing steps
Solution Approach 1:
By merging the semiconductor chip and converter layer into a single integrated component, the patent reduces the number of separate manufacturing processes and handling steps. This integration simplifies production workflows, reduces labor costs, and maintains high conversion efficiency, thereby lowering manufacturing costs while preserving efficiency
Solution Approach 2:
The converter layer is designed to convert the wavelength of light emitted by the semiconductor chip (e.g., blue or ultraviolet) into desired wavelengths (e.g., green, yellow, red) through phosphor materials. This color conversion capability allows a single high-efficiency laser chip to produce multiple colors, reducing the need for multiple chips and associated manufacturing costs while maintaining high efficiency
3Ease of manufacture
If light-emitting diodes are used to achieve low manufacturing costs, then the component can be produced inexpensively, but efficiency droop occurs at increased outputs making them unsuitable for projection applications
Solution Approach 1:
The converter layer acts as an intermediary between the semiconductor chip and the final light output. The chip generates high-intensity blue or ultraviolet light with high efficiency, and the converter layer mediates this by converting the wavelength to produce the desired colors. This intermediary approach allows the system to operate at high outputs without efficiency droop, as the chip itself maintains high efficiency while the converter enables color diversity suitable for projection applications
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 results in a highly efficient, cost-effective light-emitting component suitable for various applications, including projection and horticulture, by simplifying the manufacturing process and enhancing luminance through monolithic integration of the converter layer, reducing manufacturing complexity and costs.
Implementation Method 1
The converter layer has converter material which is configured to convert short-wavelength radiation into long-wavelength radiation, for example electromagnetic radiation with a peak wavelength in the ultraviolet or blue spectral range into electromagnetic radiation with a peak wavelength in the green, yellow or red spectral range
Data Source
AI summary
The invention relates to a component including a semiconductor body and at least one converter layer, wherein the semiconductor body includes at least one active region having an active zone, the active zone being designed to produce electromagnetic radiation. The semiconductor body has at least one vertical recess. A side wall of the recess is formed by a vertically extending facet of the active region, said facet being a radiation passage surface of the active region. The converter layer covers the recess in a top view or at least partly fills the recess. The invention also relates to a method for producing a component.