Transparent LED Submount with Phosphor Conversion

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Solution Overview

Problem

LED chips in white LED packages are prone to degradation due to exposure to humidity and chemical atmospheres, and current packaging methods are costly and not cost-effective, making it difficult to replace conventional lighting with LED products.

Innovation Solution

The use of a transparent submount with conductive electrode plates and phosphor layers to encapsulate LED chips, allowing omnidirectional light emission while protecting against high-intensity blue light and providing mechanical and electrical support, and the adoption of flip chip techniques or silver paste/solder for cost-effective packaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If LED chips are exposed to atmosphere full of humidity or chemical, then light emission is achieved, but LED chips degrade due to environmental exposure

Engineering Contradiction:
Improvelight emissionVSAvoidLED chip degradation
Core Design Contradiction:
Illumination intensityVSReliability

Solution Approach 1:

The patent employs a encapsulation layer (thin film structure) that covers and protects the LED chip from environmental exposure to humidity and chemicals, while still allowing light to pass through. This flexible protective shell isolates the sensitive LED chip from harmful atmospheric conditions without blocking its light emission function.

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The encapsulation layer acts as an intermediary between the LED chip and the external environment. It serves as a protective barrier that mediates the interaction between the LED chip and humidity/chemicals in the atmosphere, preventing direct contact and degradation while maintaining optical transparency for light emission.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If conventional LED packaging methods are used, then LED chips are protected, but production costs increase

Engineering Contradiction:
ImproveLED chip protectionVSAvoidpackaging cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates unnecessary complex packaging components from conventional LED packaging methods. By using a simplified encapsulation layer structure instead of multiple protective layers and components, the design reduces manufacturing complexity and cost while maintaining adequate protection for the LED chip.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The encapsulation layer is designed as a simple, cost-effective protective structure that can be easily manufactured and applied. This affordable protective layer provides sufficient protection for the LED chip without requiring expensive packaging materials or complex assembly processes.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Illumination intensity

If blue LED chip emits light directly, then high intensity light is produced, but blue light damages human eyes

Engineering Contradiction:
Improvelight intensityVSAvoidblue light damage to eyes
Core Design Contradiction:
Illumination intensityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful high-intensity blue light into beneficial light by introducing a phosphor conversion layer. This layer absorbs the harmful blue light and converts it to safer, more comfortable wavelengths (yellow-green), transforming the harmful radiation into a beneficial light source that maintains illumination intensity while protecting human eyes.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The phosphor conversion layer acts as an intermediary between the blue LED chip and the human eye. It mediates the interaction by absorbing the harmful blue light and converting it to safer wavelengths, preventing direct exposure to high-intensity blue light while maintaining the lighting function.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 solution enhances the reliability and cost-effectiveness of LED packaging by ensuring omnidirectional light emission and protecting against blue light damage, making LED products more competitive in the market.

Implementation Method 1

phosphor converting a portion of the blue light from a blue LED chip into green/yellow light

Methodology Applied
Scientific EffectPhotoluminescence: Photoluminescence

Data Source

PatentUS9546762B2LED assembly
Publication Date: 2017.01.17 ENNOSTAR CORP
  • US9546762B2 patent drawing
  • US9546762B2 patent drawing
  • US9546762B2 patent drawing

AI summary

Disclosed are LED assemblies and their applications. An example LED assembly has an LED chip, a supportive structure and a transparent structure. The LED chip includes a transparent substrate, at least one LED cell, and two pads. The transparent substrate has a top surface with two terminals. The LED cell is formed on the top surface, and includes at least one light-emitting stack configured to emit light. The pad is formed on the top surface at the two terminals. The supportive structure has a transparent portion and a conductive portion. The conductive portion is connected to the transparent portion to fix the LED chip and supply electric power to at least one of the pads. The transparent structure encapsulates the LED cell.