Optical Semiconductor Light Reflecting Layer Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for forming a coating member on light emitting elements result in inefficient light extraction due to the reflection of light emitted upwards by the coating member, preventing effective outward light emission.
Innovation Solution
A method involving temporarily fixing optical semiconductor elements, filling gaps between them with a light reflecting sheet, forming a light reflecting layer on connecting surfaces, and removing excess to allow efficient light emission, along with an optional phosphor layer for wavelength conversion and improved light extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a coating member containing light reflective particles is disposed on the side surfaces of light emitting elements, then light extraction efficiency is improved, but light emitted upward is reflected back, reducing overall light output
Solution Approach 1:
The coating member is segmented into a light reflecting layer and a phosphor layer, with each layer serving a specific function. The light reflecting layer reflects light emitted from the light emitting element, while the phosphor layer converts the reflected light to different wavelengths, preventing harmful upward reflection while maintaining light extraction efficiency
Solution Approach 2:
The coating member is formed as a composite structure combining light reflective particles and phosphor particles. This composite material allows simultaneous achievement of light reflection and wavelength conversion, resolving the contradiction between improving light extraction and preventing harmful upward light reflection
2Loss of energy
If a light reflecting layer is formed on the light emitting surface, then light reflection is enhanced, but light emission is blocked
Solution Approach 1:
The coating member is divided into distinct layers: the light reflecting layer is positioned adjacent to the light emitting element to reflect light, while the phosphor layer is positioned on the outer surface to emit light. This segmentation allows the light reflecting layer to enhance reflection without blocking light emission, as the phosphor layer acts as a light-emitting interface
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 method enhances light extraction efficiency by removing light reflecting layers from light emitting surfaces and efficiently reflecting light emitted from optical semiconductor elements, while also allowing for wavelength conversion by phosphor layers to ensure effective light output.
Implementation Method 1
filling a first gap between the optical semiconductor elements that are next to each other with a light reflecting sheet and forming a light reflecting layer on the connecting surfaces
Implementation Method 2
forming a phosphor layer so as to cover at least the other surface of the LED
Implementation Method 3
a phosphor layer for wavelength conversion and improved light extraction
Data Source
Figure 1A~1E
Figure 2~3
Figure 4A~4D
AI summary
A method for producing a light reflecting layer-including optical semiconductor element includes the steps of temporarily fixing electrode surfaces of a plurality of optical semiconductor elements each having the electrode surface provided with an electrode, a light emitting surface opposing the electrode surface and provided with a light emitting layer, and a connecting surface connecting a peripheral end edge of the electrode surface to that of the light emitting surface to a temporarily fixing sheet at spaced intervals to each other; filling a first gap between the optical semiconductor elements that are next to each other with a light reflecting sheet and forming a light reflecting layer on the connecting surfaces of the plurality of optical semiconductor elements; removing the light reflecting layer attaching to the light emitting surfaces of the plurality of optical semiconductor elements; and cutting the light reflecting layer between the optical semiconductor elements that are next to each other.