Grooved Sidewall LED Structure for Lower Current Density
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Solution Overview
Problem
LED light-emitting units are prone to burnout under high current density, which is necessary for high brightness, and this high current density is not conducive to the display effect of the LED structure.
Innovation Solution
The LED structure includes a substrate with grooves on its side, where a first insulating layer is used to create epitaxial sidewalls within the grooves. Each LED light-emitting unit is located on these epitaxial sidewalls, where the area of the sidewall is greater than the maximum opening area of the groove, reducing current density and heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If high current density is injected to achieve high brightness, then illumination intensity is improved, but reliability deteriorates due to LED burnout
Solution Approach 1:
The patent transitions from planar LED growth to three-dimensional sidewall growth within grooves. By growing LED light-emitting units on the vertical sidewalls of etched grooves rather than on flat substrates, the effective emission area increases while maintaining compact footprint, thereby reducing current density requirements for achieving high brightness
Solution Approach 2:
The patent divides the LED structure into multiple independent light-emitting units grown on different sidewalls of grooves. Each groove contains one or more LED units on its sidewalls, creating segmented current paths that distribute the total current across multiple independent emission regions, reducing the current density on each individual unit
2Illumination intensity
If high current density is injected to achieve high brightness, then illumination intensity is improved, but heat generation increases causing harmful effects
Solution Approach 1:
By growing LEDs on vertical sidewalls instead of horizontal planes, the patent increases the surface area for light emission without proportionally increasing the current load. This dimensional transition allows more LED units to share the total current, reducing heat generation per unit while maintaining high overall brightness
Solution Approach 2:
The groove structure creates localized regions with enhanced heat dissipation characteristics. The sidewall geometry and surrounding structures can be optimized for thermal management in specific local areas, improving heat dissipation efficiency where it is most needed
3Reliability
If grooves with epitaxial sidewalls are used to reduce current density, then reliability is improved, but device complexity increases
Solution Approach 1:
The etched grooves serve dual purposes: they provide the structural framework for the device and simultaneously act as self-aligned masks and templates for the epitaxial growth of LED sidewalls. The groove walls automatically define the growth position and orientation, eliminating the need for separate alignment structures and reducing overall device complexity despite the three-dimensional architecture
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
This configuration reduces the current density and heat generation in the LED structure, thereby improving the display effect and preventing burnout of the LED light-emitting units.
Implementation Method 1
each groove includes at least one epitaxial sidewall
Data Source
AI summary
Provided is an LED structure and a manufacturing method thereof. The LED structure includes a substrate and multiple LED light-emitting units. Multiple grooves are disposed on a side of the substrate, and a first insulating layer is disposed on the substrate between the multiple grooves, where each groove includes at least one epitaxial sidewall, and in the groove, the area of the epitaxial sidewall is greater than the maximum opening area of the groove. Each LED light-emitting unit is located on the at least one epitaxial sidewall of the groove. In this manner, the current density of the LED structure can be reduced, the LED structure can be prevented from generating more heat, and the display effect of the LED structure can be improved.