Light-emitting Device Packages with Intermediate Refractive Layers
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Solution Overview
Problem
Current light-emitting device packages face challenges in achieving improved luminous efficiency and reducing manufacturing costs, particularly due to issues with color mixing and the need for barriers between wavelength conversion layers, which increase production complexity and costs.
Innovation Solution
The proposed solution involves a light-emitting device package design that includes multiple luminescent structures with an intermediate layer and wavelength conversion layers, where the intermediate layer has different refractive indexes and the wavelength conversion layers vertically overlap the luminescent structures, and a sealing member fills the spaces between these layers, eliminating the need for barriers and enhancing light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If barriers are added between wavelength conversion layers to prevent color mixing, then color purity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces an intermediate layer with specific refractive index (1.7-1.9) between the luminescent structure and wavelength conversion layers. This intermediary layer acts as a mediator that controls light propagation directions, preventing color mixing between adjacent wavelength conversion layers without requiring additional barrier structures. The refractive index matching reduces light scattering and improves extraction efficiency while maintaining color purity.
Solution Approach 2:
The patent changes the refractive index parameter of the intermediate layer to a specific range (1.7-1.9) that optimizes light extraction and prevents color mixing. By adjusting this physical parameter, the system achieves both color purity and simplified structure without needing complex barrier mechanisms between wavelength conversion layers.
2Adaptability or versatility
If multiple wavelength conversion layers are stacked to achieve full-color emission, then color versatility is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent combines multiple wavelength conversion layers (first, second, and third wavelength conversion layers with different phosphor materials) into a single stacked structure that emits full-color light. By merging these layers with the intermediate layer support system, the patent achieves full-color emission capability while reducing manufacturing steps compared to producing separate color components and assembling them.
Solution Approach 2:
The intermediate layer serves multiple functions simultaneously: it provides mechanical support for the stacked wavelength conversion layers, controls light propagation directions to prevent color mixing, and enhances light extraction efficiency through refractive index matching. This multi-functionality reduces the need for additional separate components, simplifying manufacturing while achieving full-color emission.
3Ease of manufacture
If conventional packaging with barriers is used, then manufacturing process is simple, but light extraction efficiency is reduced due to directional light emission
Solution Approach 1:
The intermediate layer with refractive index 1.7-1.9 acts as an intermediary that modifies light propagation directions without requiring complex barrier structures. This mediator layer redirects light that would otherwise be trapped by total internal reflection, significantly improving light extraction efficiency while maintaining manufacturing simplicity through a single-layer design.
Solution Approach 2:
By changing the refractive index parameter of the intermediate layer to a specific range (1.7-1.9), the patent optimizes light extraction efficiency. This parameter change enables the layer to effectively control light propagation angles and reduce directional emission losses, achieving high efficiency without complex manufacturing 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 design improves light extraction efficiency by reducing directional angles of emitted light and preventing color mixing, while also simplifying the manufacturing process by removing barriers between wavelength conversion layers, thereby reducing overall costs.
Implementation Method 1
The plurality of layers may be associated with different refractive indexes, respectively
Implementation Method 2
Each wavelength conversion layer may be configured to filter light emitted by a respective overlapped luminescent structure to emit light in a separate wavelength band
Data Source
AI summary
A light-emitting device package includes a plurality of luminescent structures arranged spaced apart from each other in a horizontal direction, an intermediate layer on the plurality of luminescent structures, and wavelength conversion layers on the intermediate layer, the wavelength conversion layers vertically overlapping separate, respective luminescent structures of the plurality of luminescent structures. The intermediate layer may include a plurality of layers, the plurality of layers associated with different refractive indexes, respectively. The intermediate layer may include a plurality of sets of holes, each set of holes may include a separate plurality of holes, and each wavelength conversion layer may vertically overlap a separate set of holes on the intermediate layer.