LED Package Dual Resin Light Extraction
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Solution Overview
Problem
Conventional light emitting diode (LED) packages face challenges in achieving efficient light extraction and uniformity due to limitations in the design of the resin layers and phosphor distribution, leading to reduced light efficiency and increased light loss on the side surfaces.
Innovation Solution
A light emitting device package design that incorporates a transparent second resin between the light emitting device and a reflective first resin, with a phosphor layer on top, where the second resin is disposed between the side surfaces of the light emitting device and the first resin, and an optical lens is used to enhance light extraction efficiency and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional single-layer resin structure is used, then the device structure is simple, but light extraction efficiency is reduced and light loss on side surfaces increases
Solution Approach 1:
The resin layer is divided into two distinct layers: a first resin layer (reflective material) and a second resin layer (transparent material). This segmentation allows each layer to perform its specific function - the first layer reflects light to prevent side surface loss, while the second layer extracts light efficiently, thereby reducing overall light loss without excessive structural complexity
Solution Approach 2:
The patent employs composite materials by combining reflective material (first resin) and transparent material (second resin) in a layered structure. This composite approach leverages the complementary optical properties of both materials - the reflective property of the first layer and the light-transmitting property of the second layer - to simultaneously address light extraction and light loss reduction
2Ease of manufacture
If a conventional single-layer resin structure is used, then the device structure is simple, but light uniformity is reduced
Solution Approach 1:
By segmenting the resin into two layers with different optical properties, the patent achieves better light uniformity. The first reflective layer ensures light is directed properly, while the second transparent layer allows uniform light extraction, creating a more stable and uniform light output composition
Solution Approach 2:
Different regions of the resin structure are assigned different qualities: the first layer has reflective quality to manage light direction, while the second layer has transparent quality to enable uniform extraction. This local differentiation of material properties throughout the structure improves overall light uniformity
3Productivity
If the phosphor layer is disposed directly on the light emitting device without proper resin layering, then the manufacturing process is simpler, but light extraction efficiency is reduced
Solution Approach 1:
The patent prepares the resin layer structure in advance before final assembly. The first and second resin layers are formed with specific thicknesses and material properties beforehand, ensuring that when the phosphor layer is applied, the light extraction conditions are already optimized, maintaining manufacturing efficiency while improving light extraction
4Ease of manufacture
If a thicker adhesive layer is used between phosphor layer and light emitting device, then manufacturing is easier, but light extraction efficiency is reduced
Solution Approach 1:
The patent specifies precise parameter ranges for the adhesive layer thickness (5-50 micrometers) and the second resin layer thickness (50-200 micrometers). By optimizing these dimensional parameters, the invention achieves a balance between manufacturing ease (sufficient thickness for proper bonding) and light extraction efficiency (controlled thickness to minimize light loss)
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 significantly improves light extraction efficiency, reduces light loss on side surfaces, and enhances light uniformity and reliability of the LED package, leading to improved performance and efficiency.
Implementation Method 1
improves the extraction efficiency of side light by sealing the side surface of the light emitting device with a transparent resin
Implementation Method 2
a first resin formed of a reflective material is disposed on a side surface of the phosphor layer
Implementation Method 3
an optical lens having a convex lens portion is disposed on the light emitting device
Implementation Method 4
a phosphor layer on the light emitting device
Data Source
AI summary
A light emitting device package disclosed in an embodiment of the invention includes a substrate including first and second frames; a light emitting device including a first bonding portion facing the first frame and a second bonding portion facing the second frame; a phosphor layer on the light emitting device; a first resin disposed around the upper surface of the substrate and the light emitting device; a second resin between the first resin and side surfaces of the light emitting device; and an adhesive layer between the phosphor layer and the light emitting device, wherein the adhesive layer includes a thickness thinner than a thickness of the phosphor layer, and the first resin comprises a reflective resin material and is disposed on the side surface of the phosphor layer. The second resin may include a transparent resin material, and the second resin may include a curved surface with an outer surface facing the first resin.