Light-Emitting Element With Recessed Monocrystalline Substrate
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Solution Overview
Problem
Conventional light-emitting diode (LED) manufacturing methods do not effectively utilize substrate structures to enhance light-emitting stack insulation and light scattering, limiting the efficiency and versatility of LED arrays.
Innovation Solution
A light-emitting element is manufactured using a monocrystalline substrate with recesses and protrusions, allowing for epitaxial growth of light-emitting stacks that are insulated and feature an uneven surface for improved light scattering, with conductive structures connecting the stacks in series or parallel configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional LED manufacturing methods are used with planar substrates, then the manufacturing process is simple, but the light scattering efficiency and insulation between stacks are insufficient
Solution Approach 1:
The patent applies curvature to the substrate surface by forming recesses and protrusions, replacing the conventional planar structure. This curved/uneven surface topology enhances light scattering efficiency while providing natural insulation between light-emitting stacks, thus resolving the contradiction between light scattering performance and structural complexity.
Solution Approach 2:
The patent transitions from a two-dimensional planar substrate to a three-dimensional substrate with recesses and protrusions. This dimensional change creates uneven surfaces that improve light scattering and provide vertical separation for better insulation between stacks, effectively addressing the limitation of conventional planar structures.
2Reliability
If conventional LED manufacturing methods are used with planar substrates, then the manufacturing process is straightforward, but the insulation between light-emitting stacks is insufficient
Solution Approach 1:
The uneven surface with recesses and protrusions creates physical separation and insulation barriers between adjacent light-emitting stacks. This curved topology naturally prevents electrical interference and improves reliability without requiring additional complex insulation layers or structures.
Solution Approach 2:
The substrate surface is segmented into multiple recess regions, each accommodating a light-emitting stack. This segmentation provides natural isolation between stacks, improving insulation and reliability while maintaining manufacturing feasibility through standard patterning and etching processes.
3Adaptability or versatility
If conventional LED manufacturing methods are used, then the process is well-established, but substrate structure utilization is insufficient
Solution Approach 1:
By introducing three-dimensional recess and protrusion structures on the substrate surface, the patent enhances adaptability for various applications. The uneven surface configuration can be optimized for different light scattering requirements and stack arrangements, improving versatility while maintaining compatibility with existing LED 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
The solution enhances light-emitting element efficiency and versatility by improving insulation and light scattering, enabling better performance and compatibility with various applications.
Implementation Method 1
forming a plurality of first light-emitting stacks in the plurality of recesses correspondingly
Data Source
AI summary
A light-emitting element includes: a substrate being a monocrystalline structure, comprising a plurality of recesses; and a plurality of first light-emitting stacks formed in the recesses respectively.