Phosphor Transfer Sheet Adhesive Refractive Index Optimization
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Solution Overview
Problem
The existing methods for producing white light-emitting devices are complex and costly due to the need for forming an adhesive layer on the mounted board before attaching a resin sheet containing a phosphor layer, which complicates the production process.
Innovation Solution
A transfer sheet for a phosphor layer is introduced, comprising a release substrate with a phosphor layer and an adhesive layer, where the phosphor layer is aligned in spaced relation and the adhesive layer has a higher refractive index than the phosphor layer, allowing for easy transfer and adherence to a board using the transfer sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adhesive layer is formed on the mounted board before attaching the resin sheet containing the phosphor layer, then the phosphor layer can be adhered to the board, but the production process becomes complicated and requires additional work
Solution Approach 1:
The patent combines the adhesive layer and phosphor layer into a single integrated resin sheet structure. The resin sheet contains both the phosphor particles and the adhesive material, eliminating the need for separate adhesive application steps. This merging of functions reduces production process complexity while maintaining reliable adhesion of the phosphor layer to the mounted board.
2Reliability
If an adhesive layer is formed on the mounted board before attaching the resin sheet containing the phosphor layer, then the phosphor layer can be adhered to the board, but production costs increase
Solution Approach 1:
The resin sheet integrates both adhesive and phosphor functions in a single component, reducing the number of production steps and material handling operations. This consolidation lowers production costs by eliminating redundant processes while ensuring reliable adhesion through the integrated adhesive layer within the resin sheet structure.
3Use of energy by moving object
If the refractive index of the adhesive layer is higher than that of the phosphor layer, then light extraction efficiency is improved, but material selection becomes more constrained
Solution Approach 1:
The patent optimizes the refractive index parameter of the adhesive layer material to be higher than that of the phosphor layer. This parameter change enhances light extraction efficiency by reducing total internal reflection at the phosphor-adhesive interface. The invention addresses material selection constraints by formulating the resin sheet with specific adhesive materials that meet the refractive index requirement while maintaining compatibility with phosphor particles.
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 method simplifies the production of white light-emitting devices by enabling easy adherence of the phosphor layer with reduced production costs and improved light extraction efficiency.
Implementation Method 1
an adhesive layer formed on the phosphor layer
Implementation Method 2
a phosphor layer that can convert blue light into yellow light and the white light-emitting device emits high-energy white light by color mixing
Data Source
AI summary
A transfer sheet for a phosphor layer includes a release substrate, a phosphor layer formed on the release substrate, and an adhesive layer formed on the phosphor layer.