Shaped Phosphor Member for Uniform Light Extraction
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Solution Overview
Problem
Existing light-emitting devices face inefficiencies in light emission due to suboptimal design of phosphor members, which affect the extraction and distribution of light emitted from light-emitting elements.
Innovation Solution
A phosphor member with a specific shape and structure, including a phosphor portion and a surrounding portion, is designed to efficiently emit light by optimizing the light incident and emission surfaces, and a method for manufacturing this member involves cutting a base material to create the desired surfaces and singulate the phosphor portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional phosphor member design is used, then the structure is simple and easy to manufacture, but the light emission efficiency and luminance uniformity are insufficient
Solution Approach 1:
The phosphor member is divided into multiple functional surfaces with different geometries: a light incident surface facing the light-emitting element, multiple light emission surfaces (first, second, third surfaces) oriented in different directions, and side surfaces. This segmentation allows each surface to optimize light extraction and distribution in its specific direction, improving overall light emission efficiency and luminance uniformity.
Solution Approach 2:
Different surfaces of the phosphor member are designed with specific local geometries and orientations tailored to their functions. The light incident surface has a shape matching the light-emitting element's output, while emission surfaces are oriented to distribute light uniformly in different directions. This local optimization of surface properties enhances light extraction efficiency and color uniformity without requiring complete redesign of the entire structure.
2Manufacturing precision
If the phosphor member uses a complex multi-surface geometry, then light extraction and distribution are improved, but the manufacturing process becomes more difficult
Solution Approach 1:
The patent provides detailed specifications for the light incident surface shape and orientation, as well as the emission surface geometries, that can be pre-planned and incorporated into the manufacturing process. By defining the optimal surface configurations in advance, the manufacturing process can be optimized to achieve the required precision without excessive complexity.
Solution Approach 2:
The invention specifies particular geometric parameters and orientation angles for the different surfaces that can be controlled during manufacturing. By optimizing these parameters within defined ranges, the patent achieves improved light extraction efficiency and luminance uniformity while maintaining manufacturability through conventional fabrication processes with appropriate precision control.
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 designed phosphor member enhances light emission efficiency by aligning the light incident and emission surfaces with the light-emitting element's output, improving luminance and color uniformity in light-emitting devices.
Implementation Method 1
a phosphor portion (41) including a first surface (42D) and a second surface (42E)
Data Source
Figure 1~2
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Figure 5
AI summary
A phosphor member disclosed in one embodiment includes: a phosphor portion including a first surface and a second surface; and a surrounding portion connected to an outer edge of the first surface and connected to an outer edge of the second surface. In a plan view viewed in a direction perpendicular to the first surface, the first surface has a shape including a first region with a width in a second direction perpendicular to a first direction, the width in the second direction increasing along the first direction. A maximum width of the second surface in the second direction is greater than a minimum width of the first surface in the second direction and less than a maximum width of the first surface in the second direction.