Light-Reflecting Resin Wall for LED Light Extraction
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Solution Overview
Problem
Existing light-emitting devices face challenges in achieving efficient light extraction due to incomplete coverage of light-reflecting resin in the recess, leading to areas where light is not reflected effectively.
Innovation Solution
A method involving the use of two light-reflecting resins with different viscosities is employed, where a first resin of low viscosity is used to cover a wide area at the bottom surface and a second resin of higher viscosity is used to form a light-reflecting wall around the light-emitting element, ensuring complete coverage and efficient light extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single light-reflecting resin is disposed in the recess, then the manufacturing process is simple, but it is difficult to achieve complete coverage and efficient light extraction
Solution Approach 1:
The light-reflecting resin is divided into two segments with different viscosities: a first light-reflecting resin with lower viscosity that spreads easily to cover the bottom surface, and a second light-reflecting resin with higher viscosity that forms a light-reflecting wall. This segmentation allows each resin to perform its specific function optimally, achieving complete coverage while maintaining a manageable manufacturing process.
Solution Approach 2:
Different regions of the recess receive resins with different viscosities tailored to their specific requirements. The bottom surface receives the lower viscosity resin for complete coverage, while the vertical walls receive the higher viscosity resin to maintain wall structure. This local quality approach ensures each area gets the appropriate resin properties for its function.
2Reliability
If a light-reflecting wall is formed to improve light extraction efficiency, then light extraction efficiency increases, but the manufacturing process becomes more complex
Solution Approach 1:
The first light-reflecting resin with lower viscosity automatically spreads to cover the bottom surface and provides a foundation for the second resin. The second light-reflecting resin with higher viscosity then forms the light-reflecting wall structure on top of this foundation. The system uses the properties of the materials themselves to achieve the desired structure without complex manufacturing steps.
Solution Approach 2:
The invention changes the viscosity parameter of the light-reflecting resin to create two distinct resin types with different flow characteristics. The lower viscosity resin flows to cover horizontal surfaces, while the higher viscosity resin maintains vertical wall structure. This parameter change enables the formation of a light-reflecting wall while keeping the manufacturing process relatively simple.
3Stability of the object's composition
If high viscosity resin is used to form light-reflecting wall, then the wall structure is stable, but it is difficult to dispose the resin in all parts of the recess
Solution Approach 1:
The resin disposal process is segmented into two sequential steps: first applying the lower viscosity resin that easily spreads to cover all parts of the bottom surface, then applying the higher viscosity resin that forms the stable light-reflecting wall. This segmentation allows each resin to be disposed efficiently in its optimal viscosity state.
Solution Approach 2:
The first light-reflecting resin with lower viscosity is applied in advance to cover the bottom surface and prepare the foundation. This preliminary action creates a base that supports the subsequent application of the higher viscosity resin, enabling efficient disposal of both resins in sequence.
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 approach allows for the formation of a light-emitting device with improved light extraction efficiency, as the light-reflecting wall effectively reflects light from the light-emitting element, enhancing the device's luminous flux by up to 24% compared to devices without a light-reflecting wall.
Implementation Method 1
curing the first light-reflecting resin and the second light-reflecting resin to form a light-reflecting wall
Implementation Method 2
a light-reflecting wall provided near a light-emitting element for reflecting light of the light-emitting element
Data Source
AI summary
A method of manufacturing a light-emitting device incudes providing a supporting member having a recess; disposing a light-emitting element at a bottom surface of the recess; disposing a first light-reflecting resin at the bottom surface of the recess; disposing a second light-reflecting resin in the recess, a viscosity of the second light-reflecting resin being higher than a viscosity of the first light-reflecting resin; and curing the first light-reflecting resin and the second light-reflecting resin to form a light-reflecting wall.