Quantum Dot Light Module with Diffusing and Reflective Layers

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Solution Overview

Problem

Current LED technologies face challenges in achieving high efficiency and cost-effectiveness due to the use of crystalline semiconductor materials, which require ultra-high vacuum techniques and result in high manufacturing costs, difficulty in producing multi-color outputs, and rigid substrates, while quantum dot-based LEDs suffer from low external quantum efficiency and manufacturing complexity.

Innovation Solution

A light module comprising a substrate, a conversion layer with quantum dots or nanocrystals embedded in a matrix material, and a diffusing layer to enhance light path length, along with reflective layers to minimize reabsorption, allowing for efficient conversion of input light to desired wavelengths and reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If crystalline semiconductor materials are used in LEDs, then high brightness, long lifetime, and good environmental stability are achieved, but high manufacturing costs and difficulty in producing multi-color outputs occur

Engineering Contradiction:

ImproveLED lifetime and stabilityVSAvoidManufacturing cost and multi-color production

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameters from crystalline semiconductors to colloidal quantum dots, which allows tuning of optical properties through size control rather than requiring different materials for different colors. This enables multi-color output from a single quantum dot layer, reducing manufacturing complexity while maintaining high efficiency and stability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses composite structures combining quantum dots with various matrix materials and shell layers. The core/shell quantum dot structure allows optimization of both efficiency (through shell protection) and color tuning (through core size control), achieving high reliability while enabling cost-effective multi-color production.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If quantum dots are used in LED emitter layers, then manufacturing costs are reduced and multi-color output is enabled, but external quantum efficiency drops to 0.001-0.01%

Engineering Contradiction:

ImproveManufacturing cost and multi-color capabilityVSAvoidExternal quantum efficiency

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent introduces shell layers as intermediary structures between the quantum dot core and the surrounding matrix. These shells (such as ZnS, SiO2, or polymer shells) serve as mediators that protect the core from non-radiative recombination sites at the surface, reduce aggregation effects, and improve overall quantum efficiency while maintaining the cost advantages of colloidal quantum dots.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention optimizes multiple parameters including quantum dot size, shell thickness, shell material composition, and surface ligand chemistry to maximize quantum efficiency. By controlling these parameters, the patent achieves high efficiency conversion while maintaining the manufacturing advantages of solution-processed quantum dots.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If ultra-high vacuum techniques are used for growing crystalline semiconductor layers, then defect-free layers are achieved, but high manufacturing costs and rigid substrate requirements result

Engineering Contradiction:

ImproveLayer quality and defect-free structureVSAvoidManufacturing cost and substrate flexibility

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical vapor deposition techniques (MBE, MOCVD) with solution-based colloidal synthesis methods. This substitution allows quantum dots to be grown in liquid environments at lower temperatures, eliminating the need for ultra-high vacuum equipment and enabling deposition on flexible, low-cost substrates while maintaining high structural quality through controlled nucleation and growth processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enables the production of LEDs with improved efficiency and cost-effectiveness by utilizing quantum dots in a matrix material with a diffusing layer and reflective layers, enhancing light conversion and reducing reabsorption, thereby addressing the limitations of both crystalline and quantum dot-based LEDs.

Implementation Method 1

a conversion layer with quantum dots or nanocrystals embedded in a matrix material, and a diffusing layer to enhance light path length, along with reflective layers to minimize reabsorption, allowing for efficient conversion of input light to desired wavelengths

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Implementation Method 2

a diffusing layer to enhance light path length

Methodology Applied

Scientific EffectLight scattering: Scattering

Implementation Method 3

reflective layers to minimize reabsorption

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS10539297B2Quantum dot containing light module

Publication Date: 2020.01.21 TECTUS CORP

AI summary

Light modules for converting the wavelength of light are described herein along with methods for using and making such modules and devices incorporating such modules.