Light-Emitting Device Reflective Resin Light Extraction
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Solution Overview
Problem
Light-emitting devices face challenges in achieving high light extraction efficiency and substrate durability, as existing technologies struggle to effectively manage light emission and prevent substrate deterioration.
Innovation Solution
A method of manufacturing light-emitting devices involves a substrate with through-holes and a structure comprising a light-transmissive resin and a reflective resin, where the reflective resin extends into the through-holes and forms an inclined region around the light-emitting element to reflect lateral light emissions, enhancing extraction efficiency and reducing substrate irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If light-emitting devices are designed for high luminance and low power consumption, then light extraction efficiency must be improved, but this requires complex structures that increase device complexity
Solution Approach 1:
The device is segmented into distinct functional regions: a light-emitting element mounted on a substrate, a light-transmissive resin covering the element, and a reflective resin layer with varying thickness. This segmentation allows each component to optimize its specific function while maintaining overall simplicity
Solution Approach 2:
The reflective resin is designed with non-uniform thickness, creating different optical properties in different regions. The thickness increases from the light-emitting element outward, providing enhanced light reflection in specific zones while maintaining light transmission in others, thereby improving light extraction efficiency without uniform complexity throughout the device
2Reliability
If the substrate is made more durable to resist deterioration, then substrate thickness or material strength must be increased, but this increases device weight and size
Solution Approach 1:
The device employs a composite structure combining the substrate with light-transmissive and reflective resin materials. This composite approach enhances substrate durability and protection without requiring significant increases in substrate thickness, thereby avoiding excessive weight gain while maintaining reliability
3Volume of moving object
If the substrate is made thinner to reduce device size, then substrate strength decreases and it becomes more prone to deterioration, but this reduces device reliability
Solution Approach 1:
The light-transmissive resin and reflective resin layer are applied beforehand to cover and protect the substrate. This protective layering compensates for the reduced mechanical strength of thinner substrates, allowing the substrate to be made thinner for reduced device size while maintaining durability through the cushioning effect of the resin layers
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 method enhances light extraction efficiency by reflecting lateral emissions and reduces substrate deterioration by minimizing direct light exposure, thereby improving the performance and longevity of light-emitting devices.
Implementation Method 1
reflecting lateral emissions
Data Source
AI summary
A method of manufacturing a light-emitting device includes: providing a substrate having: a first surface, a second surface opposite to the first surface, a first through-hole extending from the first surface to the second surface, and wiring on the first surface; mounting a light-emitting element on the first surface to electrically connect an electrode of the light-emitting element and the wiring; providing a cover member having a concave portion for accommodating the light-emitting element; disposing the cover member such that the cover member faces the first surface of the substrate and the concave portion accommodates the light-emitting element and leads to the first through-hole; forming a light-transmissive resin in the concave portion such that a cavity is formed between (i) part of the first surface of the substrate around the light-emitting element and (ii) the light-transmissive resin; and injecting a reflective resin material into the cavity and the first through-hole.