Light-Enhancement Device Wavelength Control for LED Efficiency
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Solution Overview
Problem
The efficiency of fluorescence powders used in LED packaging is decreased during high-temperature co-sintering processes, leading to increased manufacturing costs and reduced illumination performance due to excessive concentration.
Innovation Solution
A light-enhancement device comprising a wavelength conversion member with a light-transmissive substrate and wavelength conversion material, combined with a wavelength controlling element that reflects unconverted light back into the substrate, enhancing the reuse efficiency of the wavelength conversion material and reducing the need for increased material quantities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorescence powders are processed in high temperature during co-sintering, then the manufacturing process can be completed, but the efficiency of fluorescence powders is decreased
Solution Approach 1:
The patent separates the sintering process from the fluorescence powder attachment process. The light-transmissive plate is sintered first at high temperature to achieve structural integrity, then the fluorescence powder is attached in a subsequent low-temperature process, avoiding direct exposure to high heat that degrades fluorescence efficiency.
Solution Approach 2:
The light-transmissive plate is prepared and sintered in advance before the fluorescence powder is applied. This preliminary preparation allows the plate to reach its optimal structural state before the sensitive fluorescence material is introduced, protecting it from thermal degradation.
2Reliability
If the amount of fluorescence powders is increased to maintain efficiency after high-temperature processing, then the expected efficiency can be maintained, but the manufacturing cost is increased
Solution Approach 1:
By separating the sintering and fluorescence attachment processes, the patent eliminates the need to overcompensate with excessive fluorescence powder. The low-temperature attachment process preserves powder efficiency, so the optimal amount can be used without waste, reducing material costs.
3Reliability
If the amount of fluorescence powders is increased, then the efficiency can be maintained, but the illumination performance is decreased due to excessive concentration
Solution Approach 1:
The patent decouples the sintering process from the fluorescence powder application, allowing precise control of powder concentration. Since the powder is applied after sintering at low temperature, the optimal concentration can be achieved without the need for excessive amounts, thereby maintaining excellent illumination performance.
4Ease of manufacture
If a smooth surface is used for the light-transmissive substrate, then the manufacturing process is simpler, but the adhesion of wavelength controlling element is reduced
Solution Approach 1:
The patent applies surface roughening only to the specific region where the wavelength controlling element will be attached, rather than treating the entire surface. This localized roughening provides sufficient adhesion area for bonding while keeping the rest of the surface smooth for optical performance and ease of manufacturing.
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 solution maintains expected illumination performance while reducing production costs and prolonging the operation life of light-emitting modules by optimizing the use of wavelength conversion materials.
Implementation Method 1
The wavelength conversion material is disposed within the light-transmissive substrate, and converts a portion of light with a first wavelength into another light with a second wavelength
Implementation Method 2
The wavelength controlling element is disposed on a surface of the light-transmissive substrate, and reflects another portion of the light with the first wavelength back into the light-transmissive substrate
Data Source
AI summary
A light-enhancement device includes a wavelength conversion member and a wavelength controlling element. The wavelength conversion member includes a light-transmissive substrate and wavelength conversion material which is disposed within the light-transmissive substrate for converting a portion of light with a first wavelength into another light with a second wavelength. The wavelength controlling element is disposed on a surface of the light-transmissive substrate for reflecting another portion of the light with the first wavelength into the light-transmissive substrate and enabling the portion of the light with the second wavelength to pass through the wavelength controlling element. A roughness of the surface of the light-transmissive substrate facing towards the wavelength controlling element is configured to be 0-1 μm.