LED Electrode Layout for Light Extraction and Insulation Protection

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Solution Overview

Problem

Current light-emitting devices face challenges in enhancing light extraction efficiency, structural reliability, and reducing failure probabilities due to insulating layer damage.

Innovation Solution

The design incorporates a substrate with multiple light-emitting units, each comprising semiconductor layers and insulating layers with specific electrode coverage patterns, along with metal layers and electrode pads to optimize electrical connections and light extraction, while ensuring the insulating layers are protected to prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional light-emitting device structures are used, then manufacturing is simpler, but light extraction efficiency is insufficient

Engineering Contradiction:

Improvelight extraction efficiencyVSAvoidstructure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The device divides the light-emitting region into multiple light-emitting units arranged in an array, with each unit having independent electrode coverage patterns. This segmentation allows optimized light extraction from each unit while maintaining overall device functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the device have different electrode coverage patterns - some light-emitting units have first extension electrodes covering specific insulating layer openings, while others have second extension electrodes covering different openings. This local differentiation optimizes light extraction efficiency for each region.

Inventive Principle:

Principle #3Local quality

2Reliability

If insulating layers are exposed for electrode contact, then electrical connection is improved, but failure probability increases due to insulating layer damage

Engineering Contradiction:

Improvestructural reliabilityVSAvoidinsulating layer damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The insulating layer openings are pre-formed in specific patterns before electrode deposition. This preliminary structuring ensures that electrodes only contact insulating layer openings where intended, preventing accidental damage during subsequent manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The insulating layer openings serve as controlled intermediaries between the electrodes and the underlying semiconductor structures. By confining electrode contact to these predefined openings, the insulating layer remains intact in all other regions, preventing damage while enabling necessary electrical connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If extension electrodes cover insulating layer openings, then light extraction efficiency improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improvelight extraction efficiencyVSAvoidelectrode alignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The electrode structure is segmented into different extension electrodes (first and second) that cover different insulating layer openings. This segmentation simplifies the alignment requirements for each electrode type compared to a single complex electrode pattern.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating layer openings are pre-formed with specific patterns and positions before electrode deposition. These pre-formed openings serve as alignment guides, reducing the manufacturing precision requirements for subsequent electrode placement.

Inventive Principle:

Principle #10Preliminary action

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 improves light extraction efficiency, enhances structural reliability, and reduces the likelihood of failure by ensuring proper electrical insulation and protection of the insulating layers, leading to a more reliable and efficient light-emitting device.

Implementation Method 1

each of the plurality of light-emitting units comprises a first semiconductor layer, an active layer and a second semiconductor layer

Methodology Applied

Scientific EffectElectroluminescence: Electroluminescence

Data Source

PatentUS11942510B2Light-emitting device

Publication Date: 2024.03.26 ENNOSTAR CORP

AI summary

A light-emitting device comprises a substrate comprising a top surface; a plurality of light-emitting units formed on the top surface of the substrate comprising a first light-emitting unit, a second light-emitting unit, and one or a plurality of third light-emitting units, wherein each of the plurality of light-emitting units comprises a first semiconductor layer, an active layer and a second semiconductor layer; an insulating layer comprising a first insulating layer opening and a second insulating layer opening formed on each of the plurality of light-emitting units; a first extension electrode covering the first light-emitting unit, wherein the first extension electrode covers the first insulating layer opening on the first light-emitting unit without covering the second insulating layer opening on the first light-emitting unit; a second extension electrode covering the second light-emitting unit, wherein the second extension electrode covers the second insulating layer opening on the second light-emitting unit without covering the first insulating layer opening on the second light-emitting unit; a first electrode pad covering a part of the plurality of the light-emitting units; and a second electrode pad covering another part of the plurality of light-emitting units.