LED Device with Dual-Gravity Conversion Layers for Uniform Illumination

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Solution Overview

Problem

Light emitting diodes (LEDs) suffer from non-uniform illumination due to the greater intensity of positive light compared to lateral light, leading to deviations in color temperature and chromaticity, necessitating a high-efficiency LED device with uniform color temperature.

Innovation Solution

The LED device incorporates a substrate with electrodes and a reflector, featuring a luminescent conversion layer with different specific gravities to enhance lateral light intensity, comprising a first luminescent conversion layer with a higher density of conversion elements to match the intensity of positive light, ensuring uniform illumination and stable color temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If luminescent conversion elements are evenly distributed around the LED chip, then the structure is simple, but the illumination uniformity deteriorates due to non-uniform light intensity distribution

Engineering Contradiction:
Improvestructural simplicityVSAvoidillumination uniformity
Core Design Contradiction:
Ease of manufactureVSIllumination intensity

Solution Approach 1:

The patent applies local quality by creating two distinct luminescent conversion layers with different specific gravities: a first layer with higher specific gravity containing more luminescent conversion elements to convert positive light, and a second layer with lower specific gravity containing fewer elements to convert lateral light. This non-uniform distribution compensates for the non-uniform light intensity from the LED chip, achieving uniform illumination while maintaining manufacturing feasibility through a systematic layering approach.

Inventive Principle:
Principle #3Local quality

2Illumination intensity

If multiple luminescent conversion elements are used to enhance lateral light, then illumination uniformity improves, but color temperature stability deteriorates due to shifted wavelengths

Engineering Contradiction:
Improvelateral light intensityVSAvoidcolor temperature stability
Core Design Contradiction:
Illumination intensityVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by carefully controlling the specific gravity and concentration of luminescent conversion elements in each layer. The first luminescent conversion layer has a higher specific gravity and higher concentration of conversion elements to handle the intense positive light, while the second layer has lower specific gravity and lower concentration to handle lateral light. This parameter optimization ensures that both layers convert light to the same wavelength range, maintaining color temperature stability while achieving uniform illumination.

Inventive Principle:
Principle #35Parameter changes

3Device complexity

If luminescent conversion elements are concentrated in one layer, then manufacturing is easier, but illumination uniformity deteriorates due to insufficient lateral light conversion

Engineering Contradiction:
Improvelayer structure complexityVSAvoidlateral light intensity
Core Design Contradiction:
Device complexityVSIllumination intensity

Solution Approach 1:

The patent applies segmentation by dividing the luminescent conversion function into two separate layers with distinct characteristics. The first luminescent conversion layer, positioned closer to the LED chip, has higher specific gravity and is optimized for converting positive light. The second luminescent conversion layer, positioned farther away, has lower specific gravity and is optimized for converting lateral light. This segmentation allows each layer to specialize in converting specific light directions, achieving uniform illumination while maintaining a relatively simple overall structure that can be manufactured using conventional processes.

Inventive Principle:
Principle #1Segmentation

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 solution achieves uniform illumination and stable color temperature by optimizing the luminescent conversion layers' design, enhancing lateral light intensity to rival positive light, resulting in better-defined chromaticity and ease of mass production.

Implementation Method 1

a luminescent conversion layer with different specific gravities to enhance lateral light intensity, comprising a first luminescent conversion layer with a higher density of conversion elements

Methodology Applied
Scientific EffectLuminescent conversion: Photoluminescence

Data Source

PatentUS8647898B2LED device and method for manufacturing the same
Publication Date: 2014.02.11 ADVANCED OPTOELECTRONIC TECH INC
  • US8647898B2 patent drawing
  • US8647898B2 patent drawing
  • US8647898B2 patent drawing

AI summary

An LED device comprises a substrate, an LED chip and a luminescent conversion layer. The substrate comprises a first electrode, a second electrode and a reflector located on top faces of the first and the second electrodes. The LED chip is disposed on the first electrode and electrically connected to the first and the second electrodes. The luminescent conversion layer is located inside the reflector and comprises a first luminescent conversion layer and a second luminescent conversion layer with different specific gravities. A manufacturing method for the LED device is also provided.