Metal Phosphate Matrix for LED Thermal Management
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Solution Overview
Problem
Current optoelectronic semiconductor components, particularly LEDs, face inefficiencies due to temperature sensitivity and inadequate heat dissipation in organic matrix materials like silicone, which lead to decreased performance and shortened service life as they increase in power, and existing inorganic solutions like glass or ceramic matrices require higher temperatures that can damage phosphors.
Innovation Solution
The use of a metal phosphate matrix, formed by condensation of a metal phosphate solution, which embeds phosphor powders and provides improved thermal conductivity, temperature resistance, and weather resistance by cross-linking at increasing temperatures, allowing for separate embedding of phosphors in different layers without the need for additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic matrix materials like silicone are used to embed phosphors, then ease of manufacture is improved, but thermal conductivity and temperature resistance deteriorate
Solution Approach 1:
The patent changes the fundamental parameter of the matrix material from organic (silicone) to inorganic (metal phosphate glass), which fundamentally alters the thermal properties while maintaining manufacturability through sol-gel processing
Solution Approach 2:
The patent creates a composite material system combining metal phosphate glass matrix with embedded phosphor particles, achieving both good thermal conductivity and ease of manufacture through the specific processing method
2Temperature
If glass or ceramic matrices are used to improve temperature resistance, then temperature resistance and thermal conductivity are improved, but manufacturing complexity and phosphor damage risk increase
Solution Approach 1:
The patent changes the processing parameter from high-temperature melting (conventional glass/ceramic) to low-temperature sol-gel condensation, achieving good temperature resistance without requiring complex high-temperature manufacturing equipment
Solution Approach 2:
The patent replaces the mechanical/thermal process of high-temperature melting with a chemical process (sol-gel condensation), simplifying the manufacturing system while achieving the desired material properties
3Device complexity
If multiple phosphors are mixed in a single matrix, then device complexity is reduced, but remission increases and efficiency decreases
Solution Approach 1:
The patent segments the phosphor distribution into multiple separate layers, each containing specific phosphors in individual metal phosphate glass matrices, reducing remission while maintaining manageable device complexity through modular construction
Solution Approach 2:
The patent transitions from horizontal mixing of phosphors in a single layer to vertical stacking of multiple phosphor layers, solving the remission problem by separating phosphors in the vertical dimension while maintaining compact device structure
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 approach enhances the efficiency and service life of LEDs by reducing remission, improving thermal and weather resistance, and allowing for direct bonding of phosphor layers, while avoiding damage to phosphors at lower temperatures, thus enabling better heat dissipation and color homogeneity.
Implementation Method 1
The metal phosphate matrix is formed by condensation (chemical setting) of a metal phosphate solution. The cross-linking progresses more and more with increasing temperature
Implementation Method 2
improved thermal conductivity and better temperature resistance and weather resistance of the conversion element are achieved
Implementation Method 3
The phosphors partially or completely convert primary radiation
Data Source
AI summary
An optoelectronic semiconductor component having a light source, which emits primary radiation, a housing, and electrical terminals, wherein a conversion element, which is based on a matrix and at least two phosphors, is connected upstream of the optoelectronic semiconductor component. The matrix contains metal phosphate and preferably consists of metal phosphate. The phosphors partially or completely convert primary radiation. At least one first phosphor powder is embedded and fixed in a first inorganic matrix based on a metal phosphate, and at least one second phosphor powder is embedded and fixed in a second matrix based on a metal phosphate.