Semiconductor Lamp Air-Gap Structure for Higher Light Extraction
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Solution Overview
Problem
Automotive lamps using packaged LEDs face challenges with low mass production yield rates, high fabrication costs, and limited flexibility, along with reduced light output due to downward light being absorbed rather than reflected.
Innovation Solution
A lamp design featuring a substrate with semiconductor light-emitting devices, a flat layer, and a spacer, where an air gap is formed around the devices to reflect downward light, enhancing light extraction without additional production costs or processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If packaged LEDs are used in automotive lamps, then the lamp structure is simplified and easier to manufacture, but the mass production yield rate decreases and fabrication costs increase
Solution Approach 1:
The invention divides the lamp into two separate manufacturing components: the lamp body (substrate with wiring) and the semiconductor light-emitting devices (LED chips). These are manufactured independently and then assembled through a transfer process. This segmentation allows each component to be optimized separately for mass production, improving overall yield rate while maintaining manufacturing simplicity.
2Device complexity
If downward light from semiconductor light-emitting devices is not reflected, then the device structure remains simple, but the light extraction rate decreases
Solution Approach 1:
The invention introduces an air gap as an intermediary optical element between the semiconductor light-emitting devices and the substrate. This air gap acts as a reflective interface that redirects downward-traveling light back toward the light-emitting region, increasing light extraction efficiency without adding complex reflective coating layers or structures.
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 air gap design significantly increases the light extraction rate of the lamp by reflecting downward light, improving efficiency and reducing production costs while maintaining flexibility in lamp design.
Implementation Method 1
an air gap may be formed between each semiconductor light-emitting device and the spacer... reflecting light traveling downward to the semiconductor light-emitting device
Data Source
AI summary
Discussed is a lamp and a lamp device, and more particularly, to a lamp using a semiconductor light-emitting device, and a method of manufacturing the lamp. The lamp includes a substrate; a plurality of semiconductor light-emitting devices disposed on the substrate; a flat layer formed between the plurality of semiconductor light-emitting devices; a spacer disposed between the substrate and the flat layer; and an air gap disposed between each semiconductor light-emitting device and the spacer.