Light Emitting Component Non-Planar Phosphor Layer
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Solution Overview
Problem
Existing light emitting components with planar phosphor surfaces suffer from reduced light intensity due to heat generation and increased total reflection, limiting the quantity of output light.
Innovation Solution
A light emitting component with a wavelength converting layer featuring at least one non-planar surface, positioned above a molding compound to prevent heat-induced intensity loss and reduce reflection, along with optional light transmissible and reflective layers to enhance light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the phosphor member covers the light emitting diode directly, then the light emitting component can be packaged, but the light intensity decreases due to heat generated by the light emitting diode
Solution Approach 1:
The patent introduces a molding compound as an intermediary layer between the light emitting diode and the wavelength converting layer. This molding compound acts as a thermal barrier and mediator, allowing the phosphor materials to be positioned away from the direct heat source while still being excited by the LED light, thereby reducing heat-induced intensity loss in the phosphor powders
Solution Approach 2:
The patent segments the light emitting component into distinct functional layers: the light emitting diode, the molding compound, and the wavelength converting layer. This segmentation allows each component to perform its specific function optimally - the LED generates light, the molding compound provides structural support and thermal management, and the wavelength converting layer converts light wavelength without being directly exposed to excessive heat
2Illumination intensity
If the surface of the phosphor member is planar, then the manufacturing is simplified, but total reflection occurs easily limiting the quantity of output light
Solution Approach 1:
The patent applies curvature to the surface of the wavelength converting layer by forming at least one non-planar surface. This curved surface design reduces total internal reflection of light passing through the phosphor layer, allowing more light to escape and increasing the overall light output quantity while the layer itself remains a simple coating that can be manufactured using conventional processes
3Illumination intensity
If the phosphor powders are excited at the surface, then the excitation process is efficient, but the quantity of light output is limited due to planar surface constraints
Solution Approach 1:
The non-planar surface increases the effective surface area of the wavelength converting layer that can be excited by the LED light. The curved geometry provides more surface area for phosphor powder excitation compared to a planar surface of the same footprint, thereby increasing the quantity of light output while maintaining efficient excitation
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 non-planar surface design increases the contact area and reduces reflection, leading to improved light output and intensity by maximizing phosphor excitation and guiding emitted light effectively.
Implementation Method 1
The wavelength converting layer 24 may convert a wavelength of the light emitted by the light emitting unit 20 into another wavelength, so as to change the light color of the light emitting unit 20
Implementation Method 2
total reflection may occur easily while the light emitted by the light emitting diode 10 passes through the surface 120
Data Source
AI summary
A light emitting component includes a light emitting unit, a molding compound and a wavelength converting layer. The light emitting unit has a forward light emitting surface. The molding compound covers the light emitting unit. The wavelength converting layer is disposed above the molding compound. The wavelength converting layer has a first surface and a second surface opposite to the first surface, wherein the first surface is located between the forward light emitting surface and the second surface, and at least one of the first and second surfaces is non-planar.