Patterned Lamination Sheet for Light Emitting Devices
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Solution Overview
Problem
The existing processes for producing light emitting devices with wavelength conversion elements are costly and complex, particularly due to the need for precise attachment and handling of individual optical elements.
Innovation Solution
A patterned lamination sheet with optical elements, such as wavelength conversion elements, lens elements, and conductive layers, is attached to a flexible support film at specific locations corresponding to light emitting elements on a substrate, allowing for a heat and vacuum lamination process to bond the elements directly to the substrate, followed by removal of the support film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual optical elements are separately fabricated and bonded to light emitting devices, then wavelength conversion properties can be selectively matched, but the process becomes costly and complex
Solution Approach 1:
The patent combines multiple separate fabrication steps into a single lamination process. Optical elements are pre-arranged on a support film in the correct spatial configuration, then the entire assembly is laminated to the light emitting device substrate in one operation, eliminating the need for separate bonding of each element
Solution Approach 2:
The optical elements are pre-positioned and pre-arranged on the support film before the lamination process. This preliminary arrangement ensures correct spatial matching with light emitting elements without requiring complex alignment during the final bonding step
2Manufacturing precision
If individual optical elements are separately handled and attached, then precise placement can be achieved, but handling and processing become more difficult
Solution Approach 1:
Multiple individual optical elements are merged into a single laminated assembly on the support film. This allows the entire group of elements to be handled as one unit during processing, significantly improving ease of operation while maintaining precise placement through the pre-arranged configuration on the film
3Manufacturing precision
If optical elements are attached directly to the substrate, then precise alignment is achieved, but the process lacks flexibility for storage and repositioning
Solution Approach 1:
The support film serves as an intermediary carrier between the optical elements and the final substrate. Elements can be precisely arranged on the film, stored or transported in this intermediate state, and then transferred to the final substrate when needed, providing both precision and flexibility
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 method simplifies and reduces costs by enabling efficient and precise attachment of optical elements to light emitting devices, allowing for flexible storage and processing of the laminate structures while maintaining optical quality and thermal management.
Implementation Method 1
The wavelength converting elements may be selectively matched with a semiconductor light emitting device, to produce a desired mixture of primary and secondary light
Implementation Method 2
The film is placed on the substrate containing the light emitting elements such that the optical elements are in contact with their corresponding light emitting elements. The optical elements are laminated to the light emitting elements
Data Source
AI summary
Optical elements (130) are attached to a support film (110) at select locations, the select locations corresponding to locations of light emitting elements (140) on another substrate, e.g. the substrate of the title (150). The film is placed on the substrate containing the light emitting elements such that the optical elements are in contact with their corresponding light emitting elements. The optical elements are laminated to the light emitting elements, and the support film is removed. The optical elements may include wavelength conversion elements, lens elements, combinations of elements, and so on. Other elements, such as conductors and reflectors may also be positioned on the laminate film.