Layered Optical Member for Heat Dissipation and Light Reflectivity

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Solution Overview

Problem

Existing optical members that use only one type of light-transmissive or light-reflective material face a trade-off between heat dissipation and light reflectivity, with one characteristic being prioritized at the expense of the other.

Innovation Solution

A manufacturing method involving the use of multiple layers of inorganic materials with varying porosities and compositions, including a first light-reflective member with a higher porosity and a second light-reflective member with an even higher porosity, combined with light-transmissive members to enhance both heat dissipation and light reflectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a single type of light-reflective member is used to prioritize light reflectivity, then light reflectivity is improved, but heat dissipation deteriorates

Engineering Contradiction:

Improvelight reflectivityVSAvoidheat dissipation

Core Design Contradiction:

Illumination intensityVSTemperature

Solution Approach 1:

The light-reflective member is divided into multiple layers with different functions: a first light-reflective member layer for heat dissipation and a second light-reflective member layer for light reflection. This segmentation allows each layer to optimize for its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the light-reflective member have different properties: the first layer has high thermal conductivity for heat dissipation, while the second layer has high reflectivity for light. Each layer is positioned where its specific property is most needed.

Inventive Principle:

Principle #3Local quality

2Reliability

If a single type of light-transmissive member is used to prioritize one characteristic, then that characteristic is improved, but other characteristics such as heat dissipation and light reflectivity become insufficient

Engineering Contradiction:

Improvecharacteristic performanceVSAvoidmulti-characteristic performance

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The optical member uses a composite structure combining light-transmissive members with light-reflective members. This composite approach integrates multiple materials with different properties to achieve simultaneous optimization of heat dissipation, light reflectivity, and other characteristics that cannot be achieved with a single material.

Inventive Principle:

Principle #40Composite materials

3Temperature

If multiple layers of inorganic materials with varying porosities are used to optimize heat dissipation and light reflectivity, then heat dissipation and visibility of light are improved, but device complexity increases

Engineering Contradiction:

Improveheat dissipationVSAvoidstructure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The light-reflective members are made from porous inorganic materials formed by firing molded bodies. The porosity is controlled to optimize both heat dissipation and light reflection properties. The porous structure provides thermal management benefits while maintaining the reflective function.

Inventive Principle:

Principle #31Porous materials

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 method improves heat dissipation and visibility of light by optimizing the properties of each layer, allowing for efficient heat management and enhanced light reflection.

Implementation Method 1

firing the first molded body at a first temperature to obtain a first light-reflective member... firing the second molded body at a second temperature lower than the first temperature to obtain a second light-reflective member

Methodology Applied

Scientific EffectFiring: Sintering

Implementation Method 2

first light-reflective member... second light-reflective member... enhancing both heat dissipation and light reflectivity

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS12604580B2Optical member, light-emitting device, method for manufacturing optical member, and method for manufacturing light-emitting device

Publication Date: 2026.04.14 NICHIA CORP

AI summary

A method for manufacturing an optical member includes: preparing a first light-transmissive member and a first molded body made of an inorganic material and surrounding at least one or more lateral surfaces of the first light-transmissive member; firing the first molded body at a first temperature to obtain a first light-reflective member; bonding an upper surface of the first light-transmissive member to a lower surface of a second light-transmissive member; forming, on an upper surface of the first light-reflective member, a second molded body made of an inorganic material and surrounding at least one or more lateral surfaces of the second light-transmissive member; and firing the second molded body at a second temperature lower than the first temperature to obtain a second light-reflective member.