Light-Emitting Device With Uneven Insulation Film Patterns
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Solution Overview
Problem
Conventional light-emitting devices face challenges in achieving improved light dispersion efficiency while maintaining reduced manufacturing costs, particularly in applications requiring uniform dispersion for indoor and outdoor illumination.
Innovation Solution
The development of a light-emitting device with uneven patterns on an insulation film, such as concave or convex patterns, that overlap light-emitting elements, allowing for enhanced light dispersion and simplification of the fabrication process by using a single imprint substrate for multiple devices, reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single transparent resin layer is provided in a convex dome shape covering one light-emitting element, then the light-emitting element is protected and light extraction is facilitated, but light dispersion efficiency is insufficient for wide-area illumination applications
Solution Approach 1:
The single transparent resin layer is divided into multiple separate transparent resin layers, each covering a different light-emitting element. This segmentation allows each layer to be optimized for its specific element while collectively providing improved light dispersion across multiple elements, resolving the contradiction between protecting individual elements and achieving wide-area dispersion.
Solution Approach 2:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional stacked arrangement of multiple transparent resin layers at different heights. This dimensional change enables light to disperse in multiple directions and planes, significantly improving wide-area illumination while maintaining individual element protection.
2Adaptability or versatility
If multiple transparent resin layers are provided to improve light dispersion, then light dispersion efficiency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent forms the multiple transparent resin layers in a preliminary sequential process where each layer is deposited and cured before the next is added. This preliminary action allows each layer to be independently optimized while maintaining overall manufacturing efficiency, reducing the complexity that would arise from attempting to form all layers simultaneously.
Solution Approach 2:
Each transparent resin layer is formulated to self-align and self-level during the deposition process, utilizing surface tension and curing characteristics to automatically position itself correctly relative to the light-emitting element below. This self-service mechanism reduces the need for complex alignment equipment and manual adjustment, lowering manufacturing complexity despite the increased number of layers.
3Ease of manufacture
If conventional fabrication processes are used for multiple transparent resin layers, then manufacturing is straightforward, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple fabrication steps into a single integrated process where the transparent resin layers are deposited, patterned, and cured in sequence without requiring separate manufacturing runs for each layer. This merging of operations maintains fabrication simplicity while reducing the cumulative cost that would result from treating each layer as an independent manufacturing task.
Solution Approach 2:
The patent develops a universal fabrication process and universal transparent resin formulation that can be applied across all layers and different light-emitting element types. This multi-functionality allows the same process parameters and materials to be reused throughout production, significantly reducing per-unit manufacturing cost despite the increased complexity of producing multiple layers.
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
The solution effectively improves light dispersion efficiency and simplifies the fabrication process, making it suitable for various illumination applications while minimizing manufacturing expenses.
Implementation Method 1
a plurality of uneven patterns on the insulation film, the uneven patterns respectively overlapping respective ones of the of the one or more light-emitting elements
Implementation Method 2
each of the plurality of uneven patterns has a curved cross-sectional shape
Data Source
AI summary
Provided are a light-emitting device having improved light dispersion efficiency, a light-emitting system including the same, and fabricating methods of the light-emitting device and the light-emitting system. The light-emitting device includes one or more light-emitting elements arranged on first surface of a substrate, an insulation film formed on the first surface of a substrate so as to cover the one or more light-emitting elements, and a plurality of uneven patterns formed on the insulation film formed on each of the one or more light-emitting elements so as to be spaced apart from each other, wherein the plurality of uneven patterns are all convex patterns or concave patterns and each of the plurality of uneven patterns has a curved cross-sectional shape.