Quantum Dot Light-Emitting Structure With Moisture Barrier Layers

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Solution Overview

Problem

Quantum dots in light-emitting devices degrade due to exposure to oxygen and moisture, leading to a decrease in wavelength conversion performance.

Innovation Solution

A light-emitting device is manufactured with a light reflective member surrounded by a first barrier layer that covers the light-emitting element and inner surface, and a second barrier layer that covers the wavelength conversion member, to prevent oxygen and moisture ingress, combined with quantum dots for wavelength conversion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If quantum dots are used for wavelength conversion, then wavelength conversion performance is improved, but degradation due to oxygen and moisture exposure occurs over time

Engineering Contradiction:
Improvewavelength conversion performanceVSAvoidservice life of quantum dots
Core Design Contradiction:
ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent applies the inert atmosphere principle by creating a sealed encapsulation environment around the quantum dots using a wavelength conversion member housing and barrier layers. This encapsulation prevents oxygen and moisture from reaching the quantum dots, effectively creating a protective inert environment that maintains their optical properties and prevents degradation over time, thereby resolving the contradiction between initial performance and long-term durability

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent employs the intermediary principle by introducing barrier layers (such as aluminum oxide, silicon oxide, or silicon nitride) as mediating elements between the quantum dots and the external environment. These barrier layers act as intermediaries that block the transmission of oxygen and moisture while allowing the quantum dots to maintain their wavelength conversion function, thus protecting the quantum dots without affecting their performance

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If barrier layers are added to protect quantum dots, then degradation is suppressed, but device structure becomes more complex

Engineering Contradiction:
Improvequantum dot stabilityVSAvoidstructure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies the merging principle by integrating the barrier layer functionality directly into the wavelength conversion member structure. The wavelength conversion member housing and encapsulation layers are combined to form a unified protective structure that simultaneously serves as both the structural housing and the protective barrier, thereby reducing overall device complexity while maintaining quantum dot stability

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent employs thin film barrier layers (such as aluminum oxide, silicon oxide, or silicon nitride films) to protect the quantum dots. These thin films provide effective protection against oxygen and moisture ingress while adding minimal structural complexity and maintaining a compact device design, thus resolving the contradiction between protection and complexity

Inventive Principle:
Principle #30Flexible shells and thin films

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 barrier layers effectively suppress the degradation of quantum dots, maintaining their spectral radiation luminance over time.

Implementation Method 1

a quantum dot configured to convert light emitted by the light-emitting element

Methodology Applied
Scientific EffectWavelength conversion: Photoluminescence

Implementation Method 2

forming a light reflective member surrounding the light-emitting element

Methodology Applied
Scientific EffectLight reflection: Reflection

Implementation Method 3

forming a first barrier layer continuously covering a surface of the light-emitting element and the inner surface of the light reflective member and the top surface of the light reflective member

Methodology Applied
Scientific EffectPermeation barrier: Permeation

Data Source

PatentUS12396303B2Light-emitting device and method for manufacturing the same
Publication Date: 2025.08.19 NICHIA CORP
  • US12396303B2 patent drawing
  • US12396303B2 patent drawing
  • US12396303B2 patent drawing

AI summary

A method for manufacturing a light-emitting device including a light-emitting element and a quantum dot configured to convert light emitted by the light-emitting element includes: preparing a base and a light-emitting element disposed on the base; forming a light reflective member surrounding the light-emitting element and including an inner surface and a top surface; forming a first barrier layer continuously covering a surface of the light-emitting element and the inner surface and the top surface of the light reflective member; forming a wavelength conversion member including the quantum dot in a region surrounded by the inner surface of the light reflective member, the light-emitting element being embedded in the wavelength conversion member; and covering, with a second barrier layer, a top surface of the wavelength conversion member and at least a portion of the first barrier layer on the top surface of the light reflective member.