LED Wavelength Conversion Layer Resin Contamination Prevention
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Solution Overview
Problem
The contamination and staining of the wavelength conversion layer in LED lighting devices due to the movement of white resin on its surface, which affects light extraction efficiency and reliability.
Innovation Solution
The design includes a wavelength conversion layer with a top surface having a fine uneven structure and a resin layer positioned below it, where the resin's top surface is lower than the wavelength conversion layer's top surface, preventing resin overflow and contamination, and using inclined or recessed side surfaces to control resin spread, thereby enhancing light extraction efficiency and maintaining cleanliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If white resin is used to embed the LED and wavelength conversion layer, then structural support and protection are provided, but the resin moves on the top surface of the wavelength conversion layer causing contamination and staining
Solution Approach 1:
The patent introduces a height dimension by forming the wavelength conversion layer with a top surface that is higher than the top surface of the resin. This dimensional elevation creates a physical barrier that prevents the resin from contacting and contaminating the wavelength conversion layer, while still allowing the resin to provide structural support from below.
Solution Approach 2:
The wavelength conversion layer is formed in advance with a top surface higher than the resin surface before the resin is applied or during the encapsulation process. This preliminary height advantage ensures that when the resin is in place, it cannot overflow or move onto the elevated wavelength conversion layer, preventing contamination before it occurs.
2Reliability
If the resin surface is level with or higher than the wavelength conversion layer surface, then complete embedding and protection are achieved, but light extraction efficiency decreases due to contamination
Solution Approach 1:
The patent uses vertical dimensionality to separate the resin surface from the wavelength conversion layer surface, creating a stepped configuration where the wavelength conversion layer protrudes above the resin. This allows the resin to provide complete embedding and protection from the sides and below, while the elevated wavelength conversion layer remains accessible for light extraction without contamination.
3Ease of manufacture
If the wavelength conversion layer has a flat top surface, then manufacturing is simplified, but resin easily spreads and contaminates the surface
Solution Approach 1:
The patent forms the top surface of the wavelength conversion layer as a convex curved surface rather than a flat surface. This curvature causes the resin to naturally follow the curved contour and be contained by the elevated rim, preventing the resin from spreading onto the wavelength conversion layer while still being manufacturable through conventional processes.
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 effectively reduces contamination, enhances light extraction efficiency, and improves the reliability of the lighting device by preventing resin from contacting the wavelength conversion layer, thus maintaining the integrity of the light emitting surface.
Implementation Method 1
a wavelength conversion layer disposed on the light emitting device and converting a part of first light emitted from the light emitting device into second light having a wavelength different from that of the first light
Data Source
AI summary
A lighting may include a substrate, a light emitting device disposed on the substrate, a wavelength conversion layer which is disposed on the light emitting device and converts a part of first light emitted from the light emitting device into second light having a wavelength different from that of the first light, and a resin which is disposed on the substrate and buries the light emitting device and at least a portion of the wavelength conversion layer. An area of the top surface of the wavelength conversion layer is greater than that of the bottom surface of the wavelength conversion layer. The side surface of the wavelength conversion layer is inclined at a predetermined angle with respect to the top surface or the bottom surface.