Reflective Electrode Light Extraction for LED Manufacturing
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Solution Overview
Problem
The existing processes for manufacturing light-emitting structures, such as LEDs, are complex and costly due to numerous steps involved, which increases time and expense.
Innovation Solution
A light-emitting structure comprising a semiconductor light-emitting element with a reflective metal layer that forms a concave surface to enhance light extraction efficiency, eliminating the need for wire bonding and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire-bonding and multi-step manufacturing processes are used, then reliable electrical connections are achieved, but manufacturing complexity and time are dramatically increased
Solution Approach 1:
The patent merges the electrical connection function and light reflection function into a single integrated electrode structure. The electrode simultaneously serves as both the electrical contact point and the reflective element, eliminating the need for separate wire-bonding components and reducing the number of manufacturing steps while maintaining reliable electrical connections.
Solution Approach 2:
The electrode is designed to perform multiple functions: it provides electrical connection to the semiconductor light-emitting element and simultaneously acts as a reflective element to extract and redirect light. This multi-functional design reduces the overall component count and simplifies the manufacturing process by eliminating the need for separate wire-bonding and reflection components.
2Reliability
If traditional multi-step processes including wire-bonding are used, then proper electrical connections are established, but manufacturing time and cost are dramatically increased
Solution Approach 1:
The electrode is pre-formed with the appropriate geometry and electrical connection properties before the semiconductor light-emitting element is mounted. The preliminary formation of the electrode structure with integrated reflection and connection capabilities eliminates the need for subsequent wire-bonding steps, thereby reducing manufacturing time while ensuring proper electrical connections.
3Ease of manufacture
If flat electrode surfaces are used, then manufacturing is simpler, but light extraction efficiency is reduced
Solution Approach 1:
The electrode surface is designed with a curved or non-planar geometry that enhances light extraction efficiency. The curved surface shape helps to redirect and extract light more effectively compared to a flat surface, while the electrode can still be manufactured using standard deposition techniques, balancing manufacturing simplicity with improved optical performance.
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 reflective concave surface improves light extraction efficiency and simplifies the manufacturing process by eliminating the need for wire bonding, thereby reducing costs and time.
Implementation Method 1
the electrodes can form a concave which reflects the light emitted by the semiconductor light-emitting element
Data Source
AI summary
A light-emitting structure includes a semiconductor light-emitting element, a first connection point and a reflective element. The semiconductor light-emitting element includes a bottom surface, a top surface opposite to the bottom surface, and a side surface arranged between the bottom surface and the top surface. The first connection point is arranged on the bottom surface. The reflective element includes a first portion arranged right beneath the bottom surface, and a second portion not overlapping the bottom surface and uplifted from a lower elevation lower than the bottom surface to a higher elevation substantially equal to that of the top surface along a curved path.