LED Active Area Preservation via Segmented Electrode Design
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Solution Overview
Problem
Conventional light-emitting diodes (LEDs) face a reduction in light-emitting efficiency due to the need for a significant portion of the active layer to be removed for electrode formation, which is necessary for sequential processes like wire bonding, resulting in decreased light output.
Innovation Solution
The design incorporates a light-emitting device with physically separated units on a single substrate, featuring a contact layer, electrodes, conductive posts, a reflective layer, and conductive layers to minimize the area of the active layer removed, allowing for increased electrode area for sequential processes while maintaining light-emitting efficiency through optimized current spreading and light extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a significant portion of the active layer is removed to form electrodes for wire bonding, then the electrode area is sufficient for sequential processes, but the light-emitting efficiency decreases
Solution Approach 1:
The device is divided into multiple light-emitting units arranged in a matrix pattern on the substrate. Each unit has its own electrode structure, allowing the electrode area to be distributed across multiple smaller units rather than requiring removal of large portions of a single active layer. This segmentation enables sufficient electrode area for wire bonding while preserving the light-emitting active area in each unit.
Solution Approach 2:
The patent transitions from a conventional single-layer LED structure to a three-dimensional matrix arrangement of light-emitting units. By stacking multiple units vertically and arranging them in a grid pattern, the electrode area is expanded in the vertical dimension, allowing adequate electrode formation without compromising the horizontal active layer area needed for light emission.
2Ease of manufacture
If the active layer area is reduced to accommodate electrode formation, then electrodes can be properly formed, but the light output decreases
Solution Approach 1:
The active layer is segmented into multiple discrete light-emitting units, each maintaining its own active layer area. This allows electrodes to be formed in the spaces between units or on specific portions of units without reducing the active layer area within each emitting unit, thereby preserving light output while enabling proper electrode formation.
Solution Approach 2:
The electrode structures are nested within or between the light-emitting units in a hierarchical arrangement. The conductive posts and electrodes are positioned to interleave with the active layer units rather than overlapping them, allowing electrode formation without encroaching on the light-emitting active area.
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 configuration enhances light-emitting efficiency by reducing the area of the active layer removed and allowing for larger electrode areas, facilitating sequential processes without compromising light output, thereby improving the overall performance of the light-emitting device.
Implementation Method 1
a reflective layer formed between the first one of light-emitting units and the first electrode
Implementation Method 2
a conductive post formed between the first electrode and the contact layer
Data Source
AI summary
A light-emitting device includes a plurality of physically separated light-emitting units formed on a single substrate: a contact layer formed on a first side of the light-emitting units ; a first electrode formed on a second side of the light-emitting units: a conductive post formed between the first electrode and the contact layer; an electrical connection structure electrically connecting a first one of the light-emitting units with another a second one of the light-emitting units; a reflective layer formed between the first one of light-emitting units and the first electrode; a first conductive layer comprising a plurality of contacts formed between the first one of the light-emitting units and the reflective layer; and a second conductive layer formed between the reflective layer and the first conductive layer.