LED Filter Protective Layer for Spectrum Consistency

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Solution Overview

Problem

Existing light emitting devices, such as LEDs, face challenges in filtering and protecting the filter layers during processing and operation, leading to potential damage and variations in light spectrum output.

Innovation Solution

A method involving the attachment of a filter layer over LEDs, with a protective layer formed over the filter and a reflective layer between neighboring LEDs, where the reflective layer is thinned to expose the protective layer, ensuring the filter's protection and optimal light extraction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a filter layer is attached to LEDs, then light spectrum output can be controlled, but the filter layer is vulnerable to damage during processing and operation

Engineering Contradiction:

Improvelight spectrum output consistencyVSAvoidfilter layer durability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

A protective layer is introduced as an intermediary element between the filter layer and the external environment. This protective layer shields the filter layer from mechanical damage during processing and operation, while allowing the filter to maintain its optical function. The protective layer acts as a mediator that preserves both the fragility of the filter and the need for durability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective layer is applied in advance to the filter layer before the device undergoes processing or operation. This beforehand protection cushions the filter layer against potential damage from subsequent manufacturing steps or operational stresses, ensuring the filter remains intact and functional throughout the device lifecycle.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If a protective layer is formed over the filter, then the filter is protected from damage, but light extraction efficiency may be reduced

Engineering Contradiction:

Improvefilter layer protectionVSAvoidlight extraction efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The protective layer is implemented as a thin film that provides mechanical protection while minimizing optical interference. By using a thin film structure, the protective function is maintained while light can still pass through with minimal absorption or scattering, thus reducing energy loss and maintaining high light extraction efficiency.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The optical parameters of the protective layer (such as thickness, refractive index, and material composition) are optimized to minimize light absorption and scattering. By carefully controlling these parameters, the protective layer provides adequate mechanical protection while maintaining high light transmission, thus reducing energy loss.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If a reflective layer is added to improve light extraction, then light extraction efficiency increases, but device complexity increases

Engineering Contradiction:

Improvelight extraction efficiencyVSAvoidlayer structure complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The reflective layer is designed to serve multiple functions: it reflects light to improve extraction efficiency, provides structural support to the layered device, and can be integrated with existing mounting structures. By making the reflective layer multi-functional, the need for additional separate components is reduced, thus managing device complexity while maintaining energy efficiency benefits.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 protective layer effectively safeguards the filter from damage, maintaining consistent light spectrum output and improving light extraction efficiency by reducing color point variations and enhancing mechanical support.

Implementation Method 1

A protective layer is formed over the filter

Methodology Applied

Scientific EffectMechanical protection:

Implementation Method 2

A reflective layer is formed over the mount

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 3

A filter is attached to at least one of the plurality of LEDs

Methodology Applied

Scientific EffectOptical filtering: Filter (optical)

Data Source

PatentUS9935244B2Light emitting device including a filter and a protective layer

Publication Date: 2018.04.03 LUMILEDS SINGAPORE PTE LTD

AI summary

A method according to embodiments of the invention includes providing a plurality of LEDs attached to a mount. A filter is attached to at least one of the plurality of LEDs. A protective layer is formed over the filter. A reflective layer is formed over the mount. A portion of the reflective layer disposed over the protective layer is removed.