Light Emitter Devices With Segmented Encapsulant Layers
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Solution Overview
Problem
Conventional light emitter devices struggle to achieve optimal light output due to limitations in light extraction efficiency, primarily because they minimize the distance between LED chips and the air interface and use a single layer of encapsulant without additional clear layers.
Innovation Solution
Incorporating an additional clear layer within the device cavity and increasing the depth of the cavity to maximize the distance between the LED chip and the air interface, thereby enhancing light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the distance between LED chips and air interface is minimized, then light extraction efficiency is improved according to conventional wisdom, but light output is limited
Solution Approach 1:
The encapsulant is divided into multiple discrete layers (first encapsulant layer, second encapsulant layer, third encapsulant layer) instead of using a single layer. This segmentation allows for optimized light extraction at different depths and interfaces, resolving the contradiction by improving light output through layered structure while maintaining manageable device complexity
Solution Approach 2:
The patent introduces a vertical dimensionality change by creating multiple encapsulant layers at different depths within the cavity. The first encapsulant layer is disposed at a first depth, the second at a second depth, and the third at a third depth, maximizing the distance between LED chips and air interface in the vertical dimension. This dimensional approach improves light output without significantly increasing overall device complexity
2Illumination intensity
If a single layer of encapsulant is used, then device structure is simple, but light extraction efficiency is suboptimal
Solution Approach 1:
The single encapsulant layer is segmented into three distinct encapsulant layers with different depths and optical properties. The first encapsulant layer is disposed at a first depth, the second encapsulant layer is disposed at a second depth, and the third encapsulant layer is disposed at a third depth within the cavity. This segmentation improves light extraction efficiency by creating multiple refraction interfaces while maintaining reasonable structural complexity
Solution Approach 2:
Each encapsulant layer can have different local optical properties and depths, allowing optimization of light extraction at specific locations and depths within the cavity. The first, second, and third encapsulant layers are positioned at different depths to create localized optical enhancement zones, improving overall light extraction efficiency without requiring uniform complexity throughout the structure
3Illumination intensity
If the cavity depth is increased to maximize distance between LED chip and air interface, then light output is improved, but device dimensions are larger
Solution Approach 1:
The patent optimizes the vertical dimension by positioning encapsulant layers at specific depths (first depth, second depth, third depth) within the cavity rather than using a single deep cavity. This dimensional optimization allows light extraction enhancement without requiring excessive overall cavity depth, thus improving luminous flux while controlling device dimensions
Solution Approach 2:
The cavity depth requirement is segmented into three distinct encapsulant layer positions rather than requiring one continuous deep layer. This segmentation allows the total effective optical path length to be achieved through multiple shallower layers, improving light output while reducing the need for excessive single-layer cavity depth
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 approach results in improved light output, with increased luminous flux by approximately 3% to 5%, and allows for brighter surface mount device (SMD) type light emitter devices with enhanced brightness and efficiency.
Implementation Method 1
Conventional light emitter devices or packages employ conventional wisdom which aims at minimizing distances between the LED chips and air interface for increasing light extraction efficiency
Implementation Method 2
a single layer of encapsulant which may or may not contain one or more phosphors disposed therein
Data Source
AI summary
Light emitter devices having improved light output and related methods are disclosed. In one embodiment, light emitter devices can include a light emission area including one or more light emitting chips. The emitter device can further include a filling material at least partially disposed over the one or more light emitting chips. The filling material can include a first discrete layer of phosphor containing material and a second discrete layer of optically clear material. The device can optionally include more than one discrete layer of optically clear material. Each of the discrete layers of material can be separately dispensed within the light emission area such that the filling material is dispensed to a level that is substantially flush with an upper surface of the emitter device.