LED Substrate Structure With Mask Openings for Easier Removal
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Solution Overview
Problem
The difficulty in removing substrates during the manufacturing of light-emitting diodes (LEDs) due to substrate absorption of emitted light, leading to decreased light-emitting efficiency.
Innovation Solution
A substrate structure with a mask layer and epitaxial structure, where the mask layer has openings exposing the base, and the epitaxial structure is formed within these openings with a different material, allowing for easier substrate removal and improved light reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the substrate is used to support the light-emitting structure layer, then the structural stability is improved, but the light-emitting efficiency deteriorates due to substrate absorption of emitted light
Solution Approach 1:
The substrate structure is segmented into distinct functional layers: a base layer for structural support, a mask layer for light reflection, and an epitaxial structure for light emission. This segmentation allows each layer to perform its specific function optimally without interfering with others, resolving the contradiction between structural stability and light-emitting efficiency.
Solution Approach 2:
The mask layer acts as an intermediary between the base and the epitaxial structure. It reflects light that would otherwise be absorbed by the base, while the base provides structural support. This intermediary layer resolves the contradiction by redirecting light away from the absorbing substrate while maintaining structural integrity.
2Loss of energy
If the substrate area is reduced to improve light emission, then the light-emitting efficiency is improved, but the structural stability deteriorates
Solution Approach 1:
The structure is divided into a large base for stability and a smaller epitaxial structure for light emission. The base maintains structural stability while the smaller epitaxial region minimizes light absorption, thus resolving the contradiction between structural stability and light-emitting efficiency.
Solution Approach 2:
Different regions of the substrate structure have different functional qualities: the base region provides structural support with large area, while the epitaxial structure region provides light emission with smaller area. This local differentiation resolves the contradiction by optimizing each region for its specific function.
3Loss of energy
If a mask layer is added to reflect light, then the light-emitting efficiency is improved, but the device complexity increases
Solution Approach 1:
The mask layer serves multiple functions: it reflects light to improve emission efficiency, provides a defined interface for the epitaxial structure, and can be integrated with the base material system. This multi-functionality justifies the added layer by providing multiple benefits beyond simple light reflection.
Solution Approach 2:
The device uses composite material structures where the mask layer and base are made of different materials optimized for their specific functions. The mask layer is designed with high light reflectivity while the base provides mechanical strength, creating a composite structure that resolves the contradiction between improved light emission and increased complexity.
4Ease of operation
If the contact area between light-emitting structure layer and substrate is reduced, then the ease of substrate removal is improved, but the structural stability deteriorates
Solution Approach 1:
The contact interface is segmented such that the epitaxial structure has a smaller footprint than the base. This segmentation allows the light-emitting structure layer to be easily removed from the smaller epitaxial region while the larger base remains to provide structural stability during and after the process.
Solution Approach 2:
The mask layer is formed beforehand to define the smaller contact area of the epitaxial structure. This preliminary action creates a predefined interface that facilitates easy removal of the light-emitting structure layer while maintaining base stability throughout the manufacturing process.
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
Facilitates easy removal of the substrate and enhances light-emitting efficiency by reducing the contact area and promoting total reflection of light.
Implementation Method 1
promoting total reflection of light
Implementation Method 2
performing epitaxial growth on the base with the mask layer as a mask to form an epitaxial structure
Data Source
AI summary
A substrate structure, a method for manufacturing a substrate structure, a light-emitting device and a method for manufacturing a light-emitting device are provided. The substrate structure may include a base, a mask layer, and an epitaxial structure. The mask layer is provided on the base, where the mask layer is provided with an opening for exposing the base. The epitaxial structure is provided in the opening, where a material of the mask layer is different from a material of the epitaxial structure.