LED Light-Emitting Structure with Integrated AC Rectification

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Solution Overview

Problem

The use of LEDs as a solid-state lighting source is limited by the need for DC power, which requires additional regulator circuits and electronic devices for AC power conversion, increasing costs and reducing AC/DC conversion efficiency and LED reliability.

Innovation Solution

A light-emitting structure with a crossover metal layer and conductive connecting layers that electrically connect multiple LED units in series, eliminating the need for separate regulator circuits by using a protruding portion to overlap and connect the units directly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If regulator circuits and electronic devices are added to convert AC power to DC power for LED operation, then LED functionality is enabled, but device complexity and cost increase

Engineering Contradiction:

ImproveAC power compatibilityVSAvoidcircuit complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the power conversion function directly into the LED chip structure by integrating a rectifier circuit and capacitor within the semiconductor device itself. This consolidation eliminates the need for separate external regulator circuits and electronic devices, thereby reducing overall device complexity while maintaining AC power compatibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The LED chip is designed to perform multiple functions: light emission, rectification of AC power, and energy storage via integrated capacitor. This multi-functionality allows the device to operate directly from AC power sources without requiring additional dedicated conversion circuits, thus reducing system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If regulator circuits and electronic devices are added for AC power conversion, then LED operation on AC power is achieved, but manufacturing cost increases

Engineering Contradiction:

ImproveAC power compatibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By combining the rectifier circuit and capacitor within the LED chip structure, the patent eliminates the need for separate external components. This integration reduces the total component count and assembly steps, leading to lower manufacturing costs while maintaining AC power compatibility.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If separate regulator circuits are used for AC/DC conversion, then power conversion is achieved, but conversion efficiency decreases

Engineering Contradiction:

ImproveAC power compatibilityVSAvoidconversion efficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The integration of the rectifier circuit and capacitor directly within the LED chip minimizes energy losses associated with external connections and separate circuit boards. The close proximity of components reduces parasitic resistance and inductance, thereby improving overall AC/DC conversion efficiency.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If additional electronic devices are added for power conversion, then AC power operation is enabled, but device package size increases

Engineering Contradiction:

ImproveAC power compatibilityVSAvoidpackage size

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The patent consolidates the rectifier circuit and capacitor within the LED chip structure, eliminating the need for separate external electronic devices. This integration dramatically reduces the overall package size while enabling AC power operation.

Inventive Principle:

Principle #5Merging (Combining)

5Adaptability or versatility

If separate regulator circuits are used, then AC power conversion is achieved, but reliability and LED lifetime are reduced

Engineering Contradiction:

ImproveAC power compatibilityVSAvoidLED reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

By integrating the rectifier circuit and capacitor within the LED chip, the patent reduces the number of external connections and interfaces that could fail. This consolidation improves reliability and extends LED lifetime while maintaining AC power compatibility.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10026778B2Light-emitting structure

Publication Date: 2018.07.17 ENNOSTAR CORP

AI summary

A light-emitting structure includes an epitaxial structure including a plurality of trenches; a conductive connecting layer, disposed under the epitaxial structure; a first isolation layer; a crossover metal layer, disposed under the first isolation layer and including a plurality of protruding portions protruding into the epitaxial structure through the plurality of trenches; a second isolation layer, disposed under the crossover metal layer; a bonding layer disposed under the second isolation layer; a substrate, disposed under the bonding layer; and an electrode, electrically connected to the conductive connecting layer and disposed adjacent to the epitaxial structure in a cross-sectional view.