Laterally Segmented Conversion Elements for Optoelectronic Components
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Solution Overview
Problem
There is a need for a simplified method to manufacture conversion elements with multiple regions having different wavelength-converting properties and an optoelectronic component incorporating such elements, where existing methods are complex and require separation structures like dams or masks.
Innovation Solution
A method involving the application of multiple conversion layers on an auxiliary carrier, where each layer converts electromagnetic radiation into different wavelength ranges, and the generated layer stack is separated to create conversion elements with laterally arranged regions, eliminating the need for separation structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separation structures like dams or masks are used to create multiple converting regions, then the conversion element can have distinct wavelength-converting properties in different regions, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The patent divides the conversion element into multiple converting regions by laterally separating different conversion materials within the same layer or across stacked layers. This segmentation is achieved without physical separation structures, instead using direct lateral arrangement of materials with different wavelength-converting properties, thereby reducing device complexity while maintaining functional versatility
Solution Approach 2:
The patent merges multiple conversion materials into a single integrated conversion element structure. Different conversion materials are combined in laterally separated regions within the same element, eliminating the need for separate dams or masks and reducing overall device complexity while achieving multiple wavelength-converting functions
2Adaptability or versatility
If separation structures like dams or masks are used to create multiple converting regions, then distinct wavelength-converting properties can be achieved, but the ease of manufacture decreases
Solution Approach 1:
The conversion element is segmented into multiple functional regions through lateral arrangement of different conversion materials during the manufacturing process itself, rather than requiring post-manufacturing separation structures. This approach simplifies the manufacturing process by integrating the region-creation step into the material deposition process
Solution Approach 2:
The patent performs preliminary arrangement of different conversion materials in laterally separated regions during the manufacturing process. By pre-positioning materials with different wavelength-converting properties in their final lateral configurations before complete assembly, the need for complex separation structures and additional manufacturing steps is eliminated
3Productivity
If conversion layers are applied on an auxiliary carrier and then separated, then a plurality of conversion elements can be efficiently produced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent creates a layer stack with laterally separated conversion materials that can be simultaneously separated into multiple identical conversion elements. This segmentation approach allows one layer stack to yield multiple conversion elements with consistent lateral region arrangements, improving productivity while maintaining simple individual element structures
Solution Approach 2:
The layer stack structure serves multiple functions: it contains all conversion materials needed for multiple conversion elements, maintains lateral region separation, and enables simultaneous production of multiple identical elements. This multi-functionality improves productivity without requiring additional complex processing steps
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 allows for the efficient and simplified production of conversion elements with distinct wavelength-converting regions, enhancing the efficiency and brightness of optoelectronic components by eliminating the need for separation structures and enabling better light mixing.
Implementation Method 1
a first conversion layer converting electromagnetic radiation of a first wavelength range into electromagnetic radiation of a second wavelength range
Implementation Method 2
a second conversion layer converting electromagnetic radiation of the first wavelength range into electromagnetic radiation of a third wavelength range
Data Source
AI summary
A method of manufacturing a plurality of conversion elements includes providing a first conversion layer on an auxiliary carrier, the first conversion layer converting electromagnetic radiation of a first wavelength range into electromagnetic radiation of a second wavelength range, applying a second conversion layer on the first conversion layer, the second conversion layer converting electromagnetic radiation of the first wavelength range into electromagnetic radiation of a third wavelength range, and separating the generated layer stack such that a plurality of conversion elements are generated, wherein each conversion element includes at least one first converting region having material of the first conversion layer, each conversion element includes at least one second converting region having material of the second conversion layer, and the converting regions are arranged laterally side by side.