LED Array Cell Layout With Phosphor Covers for Heat Dissipation
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Solution Overview
Problem
High power LED light-emitting device arrays face efficiency decreases due to heat generation from phosphor-coated or filled covers, leading to reduced light-conversion efficiency and die efficiency, along with issues like delamination and internal reflection losses.
Innovation Solution
A thermally conductive support member with a phosphor-coated or filled cover attached to its upper face, allowing heat transfer to a thermally conductive substrate, and proper heat dissipation through a heat sink to prevent overheating, combined with optimized cell design to minimize cross-talk and phosphor quantity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If phosphor-coated or filled covers are used to convert monochromatic light to desired light properties, then light with desired properties is achieved, but heat generation increases causing efficiency decrease
Solution Approach 1:
The patent divides the light-emitting device into multiple individual cells, each with its own phosphor-coated cover. This segmentation allows heat to be distributed and dissipated from multiple separate sources rather than concentrating heat in a single large phosphor-coated cover, thereby maintaining light conversion efficiency while managing heat generation.
Solution Approach 2:
The patent introduces a heat sink as an intermediary component between the phosphor-coated covers and the environment. The heat sink absorbs and dissipates heat generated by the phosphor conversion process, preventing heat accumulation that would otherwise reduce light conversion efficiency.
2Power
If multiple light-emitting dice are arranged in a package to increase light intensity, then high light intensity is achieved, but heat generation and efficiency loss increase
Solution Approach 1:
The patent segments the light-emitting device into multiple individual cells, each containing one or more light-emitting dice. This segmentation allows each cell to be independently optimized and cooled, preventing the cumulative heat effect that would occur if all dice were packed in a single package, thereby maintaining higher overall efficiency while achieving high light intensity.
3Illumination intensity
If phosphor quantity is increased to improve light conversion, then desired light properties are achieved, but heat generation and delamination risk increase
Solution Approach 1:
The patent distributes phosphor-coated covers across multiple individual cells rather than using a single large phosphor coating. This segmentation reduces the total phosphor quantity needed in each cell, decreasing heat generation and thermal stress per cell, thereby reducing delamination risk while maintaining overall light conversion through the combined effect of multiple cells.
4Productivity
If cell design is optimized to minimize cross-talk, then individual cell efficiency is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the cross-talk problem by providing optical isolation between individual cells. Each cell is designed as an independent optical unit with its own phosphor-coated cover, preventing light from one cell from interfering with adjacent cells. This extraction of the cross-talk issue allows each cell to operate at maximum efficiency without requiring complex active control mechanisms.
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 configuration maintains LED efficiency by effective heat management and reduces the risk of delamination and internal reflection losses, enhancing the reliability and economic production of high power LED arrays.
Implementation Method 1
A thermally conductive support member with a phosphor-coated or filled cover attached to its upper face, allowing heat transfer to a thermally conductive substrate
Implementation Method 2
proper heat dissipation through a heat sink to prevent overheating
Implementation Method 3
use a phosphor material to convert monochromatic light from a blue or ultra-violet color emitting LED die or dice to a light with the desired properties
Data Source
AI summary
A light-emitting device and a method for manufacturing the light-emitting device is disclosed. Such a light-emitting device comprises a substrate, a plurality of cells disposed on the substrate, and a plurality of semiconductor dice, wherein each of the plurality of cells accommodates at least one of the plurality of dice. Each of the plurality of cells may be filled with an encapsulant, phosphor or a mixture of an encapsulant with phosphor to control light characteristics of the light-emitting device. In an alternative aspect, cells may be filled with an encapsulant, and comprise a transparent cover coated with or filled with phosphors to control light characteristics of the light-emitting device.