Light Emitting Device Groove Structure for Uniform Light Extraction
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Solution Overview
Problem
Conventional light emitting devices with plate-like optical layers exhibit uneven light distribution and color unevenness due to the difference in thickness between the lower and upper surfaces, leading to reduced light extraction efficiency and luminance consistency.
Innovation Solution
A light emitting device is manufactured by bonding light emitting elements to a light-transmissive substrate with a groove structure, where a light guiding member covers the lateral surfaces and a light-transmissive member with a projecting portion is directly bonded to the light emitting element, reducing thickness variations and minimizing light absorption or reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a plate-like optical layer with lower surface greater than upper surface is used, then light extraction efficiency is improved, but light distribution becomes uneven and color unevenness occurs
Solution Approach 1:
The patent applies local quality by creating a groove structure at specific locations (outer peripheral portion) of the light-transmissive substrate, rather than uniformly modifying the entire substrate. This localized structural change allows light to be effectively extracted from peripheral regions without compromising the overall uniformity of light distribution across the light emitting surface.
Solution Approach 2:
The patent segments the light-transmissive substrate by forming grooves that divide it into different regions (central portion and outer peripheral portion). This segmentation allows different light management strategies to be applied to different regions, with the groove structure specifically addressing light extraction in the peripheral region while maintaining uniformity in the central region.
2Loss of energy
If thickness variation is increased in plate-like optical layer, then light extraction efficiency is improved, but color unevenness and luminance consistency deteriorate
Solution Approach 1:
The groove structure introduces local thickness variation only at the outer peripheral portion of the light-transmissive substrate, while maintaining relatively uniform thickness in the central portion. This localized approach allows the patent to improve light extraction efficiency at peripheral regions without causing significant color unevenness across the entire light emitting surface.
3Loss of energy
If light guiding member is disposed in groove, then light extraction efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the light guiding member with the groove structure, where the light guiding member is disposed within and integrated into the groove formed in the light-transmissive substrate. This merging approach allows the light guiding function to be achieved without adding separate, complex structural elements, as the groove itself provides the necessary configuration for light guidance and extraction.
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 enhances light extraction efficiency and reduces color unevenness at the light emitting surface, improving luminance consistency and mechanical strength while preventing light absorption or reflection issues.
Implementation Method 1
disposing at least one light guiding member in the groove to continuously cover the groove and the outer peripheral lateral surfaces of adjacent ones of the plurality of light emitting elements
Implementation Method 2
a light-transmissive member with a projecting portion is directly bonded to the light emitting element, reducing thickness variations and minimizing light absorption or reflection
Data Source
AI summary
A method of manufacturing a light emitting device includes: bonding a plurality of light emitting elements each having an outer peripheral lateral surface onto a light-transmissive substrate; forming at least one groove on the light-transmissive substrate to surround an outer periphery of each of the plurality of light emitting elements; disposing at least one light guiding member in the groove to continuously cover the groove and the outer peripheral lateral surfaces of adjacent ones of the plurality of light emitting elements; and singulating the light-transmissive substrate at a position between adjacent ones of the plurality of light emitting elements, to obtain a plurality of light emitting devices in each of which at least one of the light emitting elements is bonded to a single light-transmissive member.