LED Resin Layer Reflective Portion Color Uniformity
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Solution Overview
Problem
Conventional light-emitting devices using LED elements and wavelength conversion materials suffer from color unevenness due to differences in optical path lengths within the resin layer, leading to undesirable color distribution when projected through condensing optical components.
Innovation Solution
A light-emitting device design featuring a substrate with an LED element, a resin layer containing a wavelength conversion material, and a reflective portion formed over a thin film portion of the resin layer, which prevents direct emission of light from the thin film portion and reflects it back to the convex portion, ensuring uniform light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the thin resin layer around the hemispherical resin layer is removed by sandblasting, then color unevenness is reduced, but the hemispherical resin layer may be damaged
Solution Approach 1:
The patent applies a reflective material specifically to the thin resin layer region surrounding the hemispherical layer, leaving the hemispherical layer itself untouched. This localized treatment eliminates the need for damaging removal processes like sandblasting, as the reflective coating prevents the thin layer from emitting unwanted light while preserving the integrity of the fluorescent hemispherical layer.
Solution Approach 2:
Instead of removing the thin resin layer that causes color unevenness (a harmful effect), the patent converts this problematic layer into a beneficial reflective element by coating it with reflective material. The previously harmful thin layer now serves to reflect light back through the hemispherical layer, improving color uniformity without requiring destructive removal processes.
2Manufacturing precision
If a reflective portion is formed over the thin film portion, then light from the thin film is reflected back to mix with convex portion light, but device complexity increases
Solution Approach 1:
The patent merges the reflective portion formation with the existing resin layer structure. The reflective material is applied directly to the thin resin layer that is already present around the hemispherical layer, combining the reflective function with the existing structural element rather than adding a completely separate component. This integration minimizes additional complexity while achieving the desired light mixing effect.
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
This design effectively alleviates color unevenness by mixing light from the thin film and convex portions, resulting in uniform color distribution without compromising production yield.
Implementation Method 1
a wavelength conversion material such as a fluorescent material in order to provide light emission with desired color such as white light emission
Implementation Method 2
a reflective portion which is formed over the thin film portion around the convex portion of the resin layer
Data Source
AI summary
A light-emitting device having an LED element and a resin layer including a convex portion covering the LED element can suppress color unevenness to achieve light emission with uniform color distribution. The light-emitting device can include a substrate, an LED element mounted on the substrate, a resin layer which contains a wavelength conversion material and is formed on the substrate to cover the LED element, the resin layer including a convex portion directly covering the LED element and a flat thin film portion extending around the convex portion, and a reflective portion which is formed over the thin film portion around the convex portion. A diffusion portion can be formed to cover the convex portion of the resin layer.