Patterned Interface for Light Extraction in LED Devices
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Solution Overview
Problem
Existing light-emitting diode (LED) technologies face challenges in enhancing luminance due to limitations in controlling surface roughness and quality of epitaxy layers, leading to poor light extraction efficiency and reproducibility issues in mass production.
Innovation Solution
A light-emitting device with a patterned interface composed of distinct, predetermined structures arranged in a specific pattern, where the patterned interface is formed between the substrate and the epitaxy layer stack or on the surface of the epitaxy layer stack, utilizing Monte Carlo simulation to generate a random pattern arrangement for improved light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mechanical polishing is used to create surface roughness, then light extraction efficiency is improved, but control over roughness depth and width becomes difficult and reproducibility deteriorates
Solution Approach 1:
The patent divides the surface into discrete patterned structures (protrusions or recesses) with specific geometries rather than creating continuous random roughness. This segmentation allows each structure to be precisely controlled in terms of size, shape, and position, while collectively providing effective light extraction enhancement.
Solution Approach 2:
The patent creates patterned structures with specific local geometries (such as cones, pyramids, or holes) that are strategically designed to interact with light at the interface. Each local structure has optimized dimensions and shapes tailored for light extraction, rather than relying on uniform random roughness throughout the surface.
2Illumination intensity
If mechanical polishing is used to create surface roughness, then light extraction efficiency is improved, but quality of epitaxy layers deteriorates due to formation on un-uniform surface
Solution Approach 1:
The patent forms the patterned structures on the substrate surface before performing mechanical polishing or epitaxial growth. This preliminary structuring creates a controlled template that guides subsequent processing, ensuring that epitaxy layers grow on a pre-defined, uniform pattern rather than on randomly polished surfaces, thereby maintaining layer quality.
Solution Approach 2:
The patent changes the approach from modifying surface topology through polishing to defining surface geometry through pattern formation. By controlling the geometric parameters of the patterned structures (size, shape, spacing) during fabrication rather than relying on polishing-induced roughness, the method maintains both light extraction efficiency and epitaxy layer quality.
3Illumination intensity
If random surface roughness is created by mechanical polishing, then light extraction efficiency is improved, but reproducibility in mass production deteriorates
Solution Approach 1:
The patent transitions from uncontrolled random roughness parameters to controlled pattern parameters with defined geometries and dimensions. This parameter control enables consistent reproduction of light extraction enhancement across mass production, as each patterned structure can be precisely fabricated with specified tolerances.
Solution Approach 2:
The patent uses master templates or masks to replicate identical patterned structures across the substrate surface. This copying approach ensures that every device receives the same precise pattern geometry, enabling high reproducibility in mass production while maintaining effective light extraction enhancement.
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 patterned interface enhances light extraction efficiency by uniformly spreading light emitted from the active layer, improving reproducibility and stability in mass production while maintaining control over the quality of epitaxy layers.
Implementation Method 1
The patterned interface enhances light extraction efficiency by uniformly spreading light emitted from the active layer
Data Source
AI summary
The present disclosure provides a light-emitting device having a patterned interface composed of a plurality of predetermined patterned structures mutually distinct, wherein the plurality of predetermined patterned structures are repeatedly arranged in the patterned interface such that any two neighboring patterned structures are different from each other. The present disclosure also provides a manufacturing method of the light-emitting device. The method comprises the steps of providing a substrate, generating a random pattern arrangement by a computing simulation, forming a mask having the random pattern arrangement on the substrate, and removing a portion of the substrate thereby transferring the random pattern arrangement to the substrate.