LED Electrode Sidewall Protrusion for Higher Light Output

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Solution Overview

Problem

Existing light-emitting devices face challenges in achieving good quality and cost-effectiveness, with previous manufacturing methods not fully optimizing electrode design for efficient light emission and structural integrity.

Innovation Solution

The light-emitting device features a first outermost sidewall with a light-emitting diode and an electrode that includes a segment extending beyond the side surface, with protrusions from the segment to the sidewall, providing a conductive path for electroplating and improving light intensity and reducing forward voltage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the electrode is designed with a protrusion extending to the sidewall, then light emission efficiency is improved and forward voltage is reduced, but the device complexity increases

Engineering Contradiction:
Improvelight emission efficiencyVSAvoidelectrode structure complexity
Core Design Contradiction:
Illumination intensityVSDevice complexity

Solution Approach 1:

The electrode is divided into multiple segments including a pad region, an extending region, and a protrusion region. This segmentation allows each part to serve specific functions: the pad provides electrical connection, the extending region increases conductive path length to reduce resistance and forward voltage, and the protrusion enhances light extraction efficiency by creating additional light-emitting surfaces.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The electrode structure implements local quality variations where different regions have different geometries and functions. The protrusion region has increased surface area for light emission, the extending region has optimized thickness for electrical conductivity, and the pad region has larger area for mechanical and electrical connection to the chip.

Inventive Principle:
Principle #3Local quality

2Strength

If the electrode segment extends beyond the side surface with protrusions, then structural integrity is improved, but manufacturing complexity increases

Engineering Contradiction:
Improvestructural integrityVSAvoidmanufacturing complexity
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The electrode structure is designed with pre-formed protrusions and extending regions that are created during the electrode fabrication process itself, rather than requiring subsequent mechanical processing. The electrode pattern is directly formed with the desired three-dimensional geometry through deposition and lithography steps, integrating structural reinforcement into the manufacturing flow.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The electrode structure incorporates nested functional regions where the protrusion contains the extending region, which in turn contains the pad region. This nested configuration allows multiple functions to be integrated within a compact footprint, providing both structural integrity and electrical functionality without requiring separate components or assembly steps.

Inventive Principle:
Principle #7Nested doll (Nesting)

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 design enhances light emission efficiency, reduces forward voltage, and improves the structural integrity of the light-emitting device, addressing the challenges of quality and cost-effectiveness in previous technologies.

Implementation Method 1

The electrode has a segment formed on the pad to extend beyond the side surface, and a first protrusion extending from the segment to the first outermost sidewall, providing a conductive path for electroplating

Methodology Applied
Scientific EffectElectroplating: Electroplating

Data Source

PatentEP3054492B1Light-emitting device
Publication Date: 2024.04.17 EPISTAR CORP
  • EP3054492B1 patent drawingFigure 1A
  • EP3054492B1 patent drawingFigure 1B
  • EP3054492B1 patent drawingFigure 1C

AI summary

This disclosure discloses a light-emitting device. The light-emitting device has a first outermost sidewall and includes a light-emitting diode and an electrode. The light-emitting diode has a pad and a side surface. The electrode has a segment formed on the pad to extend beyond the side surface, and a first protrusion extending from the segment to the first outermost sidewall.