Laterally Structured Phosphor Layer via Electrophoretic Deposition
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Solution Overview
Problem
Existing methods for producing laterally patterned layers, particularly for luminescent material plates in optoelectronic semiconductor components, face challenges in achieving efficient and accurate material distribution and optical isolation between pixels, leading to suboptimal contrast and optical crosstalk.
Innovation Solution
A method involving a carrier with a first and second electrically conductive layer, an insulation layer, and an etching mask is used to selectively deposit luminescent and radiation-opaque materials using electrophoresis, allowing for precise patterning and optical isolation between pixels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce laterally patterned luminescent layers, then material distribution and patterning can be achieved, but manufacturing efficiency is low and manufacturing precision is insufficient leading to optical crosstalk between pixels
Solution Approach 1:
The patent divides the luminescent layer into multiple independently controllable pixels or pixel groups, with each pixel having its own electrode structure. This segmentation enables selective electrophoretic deposition of luminescent particles into individual pixels, achieving high patterning accuracy while maintaining manufacturing efficiency through parallel processing capabilities
Solution Approach 2:
The patent replaces conventional mechanical or photolithographic patterning methods with an electric field-based electrophoresis process. By applying voltage to specific electrodes, luminescent particles are selectively transported and deposited into target pixels, eliminating the need for complex mechanical masking or chemical etching processes, thereby improving both precision and efficiency
2Illumination intensity
If luminescent material is deposited to enhance brightness, then optical contrast between pixels is improved, but optical crosstalk between adjacent pixels increases
Solution Approach 1:
The patent implements local quality control by providing each pixel with dedicated electrodes and independently controlling the electrophoretic deposition process for each pixel. This ensures that luminescent particles are precisely positioned only within the boundaries of their intended pixel, enhancing local brightness while preventing particles from migrating into adjacent pixels, thus eliminating optical crosstalk
Solution Approach 2:
The patent uses equipotential electrode structures and controlled voltage application to create distinct electric field zones for each pixel. By maintaining proper potential differences during the electrophoresis process, luminescent particles are confined to their designated pixels, achieving high brightness without optical interference between adjacent pixels
3Manufacturing precision
If complex multi-layer structures are used to achieve lateral patterning, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent transitions from planar two-dimensional patterning methods to three-dimensional control by utilizing vertical electrode structures and electric field-based particle transport. This dimensional approach allows precise lateral positioning of luminescent particles through electric field control without requiring complex lateral masking layers, reducing overall device complexity while maintaining high patterning accuracy
Solution Approach 2:
The patent introduces an electric field as an intermediary mechanism to control luminescent particle distribution. Instead of using complex physical masks or multiple lithographic layers, the electric field serves as a controllable mediator that directs particles to their precise locations, simplifying the overall device structure while achieving superior patterning precision
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 enables the production of laterally patterned luminescent material plates with high accuracy and mechanical stability, effectively preventing optical crosstalk between adjacent pixels, thereby enhancing contrast and performance in optoelectronic semiconductor components.
Implementation Method 1
a voltage is applied for a time to the first electrically conductive layer. The first electrically conductive layer is then coated with a first material by means of electrophoresis
Implementation Method 2
a voltage is applied to the second electrically conductive layer and a second material is deposited by means of electrophoresis onto the second electrically conductive layer
Data Source
AI summary
A method for producing a laterally structured phosphor layer and an optoelectronic component comprising such a phosphor layer are disclosed. In an embodiment the method includes providing a carrier having a first electrically conductive layer at a carrier top side, applying an insulation layer to the first electrically conductive layer and a second electrically conductive layer to the insulation layer, etching the second electrically conductive layer and the insulation layer, wherein the first electrically conductive layer is maintained as a continuous layer. The method further includes applying a voltage to the first electrically conductive layer and electrophoretically coating the first electrically conductive layer with a first material, and applying a voltage to the second electrically conductive layer and electrophoretically coating the second electrically conductive layer with a second material.