LED Encapsulating Sheet with Spacer Layer for Uniform Light Scattering
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Solution Overview
Problem
Existing light emitting diode (LED) devices suffer from color unevenness due to the high directivity of light emission, and previous methods for mitigating this issue, such as using a light scattering layer on top of a transparent encapsulating layer, complicate the production process and reduce efficiency.
Innovation Solution
An encapsulating sheet with a light scattering layer, a spacer layer, and an encapsulating layer is used, where the spacer layer is interposed between the encapsulating and light scattering layers, allowing light to scatter in a direction perpendicular to the thickness direction, effectively converting the LED into a surface light source while simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a light scattering layer is disposed on the upper surface of the transparent layer after encapsulating the LED chip, then color unevenness is suppressed, but the number of production steps increases and production efficiency decreases
Solution Approach 1:
The patent combines the transparent encapsulating layer and light scattering layer into a single integrated encapsulating sheet. The encapsulating sheet includes a transparent resin layer and a light scattering layer formed integrally through co-curing, eliminating the need for separate application steps while maintaining both encapsulation and light scattering functions.
Solution Approach 2:
The light scattering layer is formed in advance within the encapsulating sheet structure before LED assembly. By pre-integrating the light scattering functionality into the encapsulating sheet, the patent eliminates post-encapsulation steps and streamlines the production process.
2Manufacturing precision
If multiple separate layers (transparent layer and light scattering layer) are used to suppress color unevenness, then brightness uniformity is improved, but device complexity increases
Solution Approach 1:
The patent merges the transparent encapsulating layer and light scattering layer into a single integrated encapsulating sheet with multiple functional layers. This consolidation reduces the number of discrete components and assembly steps while maintaining the optical functions of both layers.
Solution Approach 2:
The encapsulating sheet serves multiple functions simultaneously: it provides mechanical encapsulation protection, enables light scattering to suppress color unevenness, and maintains optical transparency. This multi-functionality reduces the need for separate dedicated components.
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 ensures that the LED emits light more uniformly, reducing color unevenness and improving production efficiency by allowing the encapsulating and light scattering layers to be applied simultaneously, resulting in a higher brightness uniformity and easier manufacturing.
Implementation Method 1
a light scattering layer formed at one side in a thickness direction of the encapsulating layer and for scattering light emitted from the light emitting diode element
Data Source
AI summary
An encapsulating sheet includes an encapsulating layer for encapsulating a light emitting diode element, a light scattering layer formed at one side in a thickness direction of the encapsulating layer and for scattering light emitted from the light emitting diode element, and a spacer layer interposed between the encapsulating layer and the light scattering layer.