LED Light-Emitting Device with Segmented Resin Layers
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Solution Overview
Problem
Conventional light-emitting devices face challenges in effectively sealing lateral light emitted by LED elements, leading to reduced light efficiency and potential obstruction of upward light by the white resin used in these devices.
Innovation Solution
A light-emitting device configuration featuring a phosphor plate with a larger lower surface area than the LED element, where a white resin seamlessly covers the peripheral side surfaces of both the LED and phosphor plates, and a transparent resin covers the phosphor plate and white resin, preventing obstruction of upward light and enhancing lateral light sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If white resin is used to cover peripheral side surfaces of LED elements, then lateral light sealing is improved, but upward light transmission is obstructed
Solution Approach 1:
The peripheral side surface covering is segmented into multiple resin layers: a lower white resin layer for lateral light sealing and an upper transparent resin layer for upward light transmission. This segmentation allows each layer to perform its specific function without interfering with the other, resolving the contradiction between lateral sealing and upward transmission.
Solution Approach 2:
Different regions of the peripheral side surface are assigned different material properties: the lower portion uses white resin with high reflectivity for lateral light sealing, while the upper portion uses transparent resin with high light transmission for upward light passage. This local differentiation of material quality optimizes both functions simultaneously.
2Loss of energy
If white resin covers the upper surface of the phosphor plate, then lateral light sealing is improved, but light conversion efficiency is reduced
Solution Approach 1:
The resin covering is segmented vertically, with the white resin confined to the lower portion and the transparent resin covering the upper portion including the phosphor plate upper surface. This segmentation ensures that the white resin seals lateral light without interfering with the phosphor's light conversion function on the upper surface.
Solution Approach 2:
The white resin is extracted from the upper surface region and restricted to the lower peripheral side surface, removing the harmful effect of white resin obstruction on light conversion while preserving its beneficial lateral sealing function in the lower region.
3Illumination intensity
If transparent resin is added to cover the phosphor plate and white resin, then upward light transmission is improved, but device complexity increases
Solution Approach 1:
The transparent resin layer is designed to simultaneously cover both the phosphor plate upper surface and the white resin peripheral side surface, merging the protection and light transmission functions into a single integrated layer, thereby reducing overall device complexity.
Solution Approach 2:
The upper transparent resin layer serves multiple functions: it allows upward light transmission, protects the phosphor plate, and integrates with the white resin structure. This multi-functionality reduces the need for separate components, simplifying the overall device structure.
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 conversion efficiency by preventing the white resin from obstructing upward light and effectively seals lateral light, improving the overall light-emitting performance compared to conventional devices.
Implementation Method 1
a phosphor plate 2 including an upper surface 2a and a lower surface 2b each being larger than an upper surface 1a of the light-emitting diode element 1, and a lower surface 2b adhered to an upper surface 1a of the light-emitting diode element 1
Implementation Method 2
a white resin 4 provided on an upper surface 7a of the substrate 7, provided to a position of an upper peripheral edge 2d of the phosphor plate 2, and covering the light-emitting diode element 1 and the phosphor plate 2 except the upper surface 2a of the phosphor plate 2
Data Source
AI summary
A light-emitting device includes a substrate that includes at least a pair of electrodes, an LED element electrically mounted on the substrate, a phosphor plate adhered to an upper surface of the LED element and including an upper surface and a lower surface each having an area larger than that of the upper surface of the LED element, a white resin provided on an upper surface of the substrate and seamlessly covering a peripheral side surface of the LED element and a peripheral side surface of the phosphor plate. A lower surface of the phosphor plate is adhered to the upper surface of the LED element through a transparent adhesive.