LED Package Supports Create Degassing Openings
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Solution Overview
Problem
Current LED packages face issues with light output deterioration due to trapped gas bubbles and encapsulant trapping, which impairs light extraction efficiency, especially with mounting edges or planar interfaces between lenses and mounting surfaces.
Innovation Solution
A lighting device package design featuring a substrate with light-emitting elements, a retaining structure, an optically transmissive element, and supports that create openings for fluid movement, allowing for degassing and reducing the likelihood of encapsulant and gas bubble trapping, thereby enhancing light extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a mounting edge or seating shelf is used to support the lens, then the lens is securely positioned, but gas bubbles become trapped and light extraction efficiency deteriorates
Solution Approach 1:
The continuous mounting edge or seating shelf is segmented by introducing openings that allow gas bubbles to escape while still providing adequate support for the lens. The support structure is divided into sections that maintain mechanical stability while creating pathways for degassing.
Solution Approach 2:
The harmful gas bubbles are extracted from the encapsulation volume by providing dedicated escape pathways through the mounting structure. The openings in the mounting edge or seating shelf serve as extraction channels that remove gas bubbles before they can cause light scattering.
2Ease of manufacture
If a planar mounting surface is used for the lens, then manufacturing is simplified, but encapsulant and gas bubbles are easily trapped at the interface
Solution Approach 1:
The planar mounting surface is segmented by introducing openings that disrupt the continuous interface between the lens and mounting surface. These openings prevent encapsulant and gas bubble accumulation while maintaining the overall simplicity of the planar mounting approach.
Solution Approach 2:
The trapped encapsulant and gas bubbles are extracted through the openings in the mounting surface. The openings serve as extraction pathways that remove harmful materials from the lens-interface region while preserving the ease of manufacture associated with planar surfaces.
3Reliability
If the LED package is sealed to protect internal components, then environmental protection is improved, but light extraction efficiency deteriorates due to trapped gas bubbles
Solution Approach 1:
The sealing structure is modified locally by introducing openings in the mounting edge or seating shelf. These localized modifications allow gas bubbles to escape from specific regions while maintaining the overall sealed environment that protects internal components from environmental damage.
Solution Approach 2:
Gas bubbles are extracted from the encapsulation volume through the openings in the sealed structure. The sealed package maintains environmental protection while the openings provide extraction pathways for gas bubbles, preventing light scattering without compromising overall sealing integrity.
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 design effectively prevents gas bubble trapping and enhances light extraction efficiency by providing pathways for degassing, leading to improved light output and reduced scattering, thus overcoming the limitations of existing LED package configurations.
Implementation Method 1
The two or more supports are disposed to provide two or more openings for the volume for movement of fluid therethrough
Implementation Method 2
an optically transmissive element coupled to the substrate and positioned to intersect a path of electromagnetic radiation emitted by the one or more light-emitting elements
Implementation Method 3
a light transmissive encapsulation material positioned within a volume defined by the substrate, the optically transmissive element and the retaining structure, the encapsulation material thereby at least partially encapsulating the one or more light-emitting elements therein
Data Source
AI summary
The present invention provides a lighting device package that is configured to enable degassing of the lighting device package. The lighting device package comprises a substrate upon which is operatively mounted one or more light-emitting elements and a retaining structure which is coupled to the substrate and configured to circumscribe the one or more light-emitting elements. In addition, the lighting device package includes an optically transmissive element, wherein two or more supports are configured to provide a separation between the optically transmissive element and the substrate or retaining structure. The volume defined by the substrate, retaining structure and the optically transmissive element, is partially or completely filled with an encapsulation material, thereby forming the lighting device package. In particular, the supports create a series of openings for the volume defined by the substrate, retaining structure and the optically transmissive element, wherein these openings provide for movement of fluid therethrough.