Reflective Resin Layer Geometry for Side-Emitting LED Extraction
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Solution Overview
Problem
Current light emitting devices have limitations in achieving high light extraction efficiency, as existing substrates and reflective materials do not effectively enhance the reflection and emission of light from light emitting elements.
Innovation Solution
A light emitting device is designed with a substrate and a reflective resin layer containing a first reflective material and a first resin, featuring a first flat part, a second flat part with a smaller thickness, and a protruded part that contacts the light emitting element, optimizing light reflection and extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high reflectance material is used as the substrate to increase light extraction efficiency, then light extraction efficiency is improved, but thermal resistance increases and brightness is limited
Solution Approach 1:
The reflective resin layer is segmented into multiple functional regions: a first flat part for general light reflection, a second flat part with smaller thickness for light emitting element placement, and a protruded part for enhanced lateral face contact. This segmentation allows different regions to perform specialized functions that collectively improve light extraction while managing thermal properties.
Solution Approach 2:
Different regions of the reflective resin layer are given different thicknesses and geometries to optimize local performance. The protruded part has larger thickness for maximum lateral contact with light emitting elements, the second flat part has smaller thickness for proper element positioning, and the first flat part provides overall structural support. This local quality variation enhances both light extraction efficiency and thermal management.
2Ease of manufacture
If the reflective resin layer has uniform thickness, then manufacturing is simplified, but light extraction efficiency from lateral faces is insufficient
Solution Approach 1:
The reflective resin layer is divided into distinct thickness zones (first flat part, second flat part, and protruded part) that can be formed through a single molding process. This segmentation enables complex three-dimensional geometry to be achieved while maintaining manufacturing simplicity through one-step formation.
Solution Approach 2:
The reflective resin layer transitions from a two-dimensional uniform layer to a three-dimensional structure with varying thickness. The protruded part extends vertically to contact lateral faces of light emitting elements, adding a height dimension that enables enhanced optical interaction without complicating the manufacturing process.
3Device complexity
If conventional substrates are used, then device structure is simple, but light extraction efficiency and luminous flux are insufficient
Solution Approach 1:
The reflective resin layer is formed as a composite material containing reflective particles dispersed in a resin matrix. This composite structure combines the light reflection properties of reflective materials with the structural and adhesive properties of the resin, achieving enhanced luminous flux while maintaining structural simplicity and ease of integration with light emitting elements.
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 described configuration significantly increases light extraction efficiency by effectively reflecting light emitted from the lateral faces of the light emitting elements, leading to improved luminous flux and reduced thermal resistance, allowing for higher brightness and efficiency compared to conventional devices.
Implementation Method 1
The reflective resin layer is disposed on the substrate and contains a first reflective material... effectively reflecting light emitted from the lateral faces of the light emitting elements
Data Source
AI summary
A light emitting device includes a substrate, a reflective resin layer, and a light emitting element. The reflective resin layer is disposed on the substrate and contains a first reflective material and a first resin. The reflective resin layer including first flat part having a first thickness, a second flat part having a second thickness smaller than the first thickness, and a protruded part having a third thickness larger than the first thickness. The light emitting element is disposed on the second flat part of the reflective resin layer, with a portion of a lateral face of the protruded part of the reflective resin layer being in contact with a portion of a lateral face of the light emitting element.