Light-Emitting Module Gap Structure for Higher Light Extraction
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Solution Overview
Problem
Conventional light-emitting modules face challenges in achieving high light extraction efficiency due to limitations in the arrangement and design of light-emitting elements, leading to reduced brightness and increased power consumption.
Innovation Solution
A light-emitting module design featuring a substrate with a support member, a wiring layer, a light-shielding member with holes, and a first light-transmissive member with convex bodies on the light extraction surfaces of the light-emitting elements, along with gaps between the light-emitting elements and the inner peripheral surfaces of the holes, enhances light extraction efficiency by directing and reflecting light upward.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional light-emitting modules use standard arrangement of light-emitting elements, then manufacturing is simpler, but light extraction efficiency is reduced
Solution Approach 1:
The patent applies local quality by creating gaps specifically at the peripheral portions of the light-emitting element where light extraction is most problematic. The gap formation is localized to regions adjacent to the light-emitting element's periphery, allowing improved light extraction efficiency without requiring complete restructuring of the entire module. This localized modification maintains manufacturing simplicity while targeting the specific areas where light extraction needs improvement.
Solution Approach 2:
The patent segments the light-emitting element structure by dividing the space around it into distinct regions: a gap region at the periphery and a light-transmissive member region covering the upper surface. This segmentation allows independent optimization of each region's function - the gap for side light extraction and the light-transmissive member for upward light extraction - thereby improving overall light extraction efficiency without complicating the entire manufacturing process.
2Illumination intensity
If light-emitting elements are arranged to improve light extraction efficiency, then brightness increases, but device complexity increases
Solution Approach 1:
The patent merges multiple light extraction functions into a unified structure. The gap and the light-transmissive member work together as an integrated light extraction system - the gap extracts light from the sides while the light-transmissive member extracts light from the upper surface. This merging approach achieves high brightness through multiple extraction paths without requiring separate complex systems for each function, thereby limiting the increase in device complexity.
Solution Approach 2:
The light-transmissive member acts as an intermediary between the light-emitting element and the external environment. It receives light from the light-emitting element's upper surface and directs it outward, while the gap serves as an intermediary pathway for lateral light extraction. These intermediary structures simplify the overall design by providing dedicated light transmission paths without requiring direct complex arrangements of multiple light-emitting elements.
3Loss of energy
If gaps are formed between light-emitting elements and hole surfaces, then light extraction efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by forming the gap structure before mounting the light-emitting element. The groove is created in the substrate during substrate preparation, establishing the gap geometry in advance. This preliminary formation of the gap structure eliminates the need for precise post-alignment operations, as the gap is already positioned correctly relative to where the light-emitting element will be mounted, thereby reducing manufacturing precision requirements while maintaining light extraction efficiency.
Solution Approach 2:
The light-transmissive member serves a dual function: it covers the upper surface of the light-emitting element and simultaneously defines part of the gap structure. By integrating these functions into a single component, the design reduces the number of separate precision-critical interfaces. The light-transmissive member's positioning requirements are simplified because it primarily needs to cover the light-emitting element's upper surface, while the gap structure is already established by the substrate groove.
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 proposed design significantly improves light extraction efficiency, reduces power consumption, and minimizes brightness unevenness across the module, enabling more efficient light emission and reduced manufacturing complexity.
Implementation Method 1
a gap arranged in contact with the wiring layer between the light-emitting element and an inner peripheral surface of the hole
Implementation Method 2
a first light-transmissive member having a convex body arranged on a light extraction surface of the light-emitting element inside the hole
Data Source
AI summary
A light-emitting module includes a substrate including a support member having a first surface, and a wiring layer arranged on the first surface. The light-emitting modules further include a light-shielding member arranged on the first surface and having a plurality of holes in plan view, a plurality of light-emitting elements respectively arranged inside the plurality of holes on the first surface and electrically connected to the wiring layer, a first light-transmissive member having a plurality of convex bodies respectively arranged on light extraction surfaces of the plurality of light-emitting elements inside the plurality of holes, and a plurality of gaps respectively arranged in contact with the wiring layer between the plurality of light-emitting elements and inner peripheral surfaces of the plurality of holes.