Textured Ceramic LED Substrates for Light Extraction
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Solution Overview
Problem
Current LED devices are costly and time-consuming to produce, and there is a need for brighter, more efficient solutions that can be manufactured quickly and at a lower cost to encourage adoption and improve return on investment.
Innovation Solution
Ceramic-based LED devices with texturized substrates featuring surface features such as pedestals, trenches, and convexly or concavely curved surfaces, which improve optics and thermal management by allowing direct heat dissipation and enhancing light extraction and reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional LED device structures and materials are used to increase lumen output and optical efficiency, then brightness and efficiency are improved, but manufacturing cost and fabrication time increase
Solution Approach 1:
The patent changes the physical parameters of the substrate surface by creating textured features (peaks, valleys, pores) instead of using conventional smooth surfaces. This texturing is achieved through chemical etching processes that modify the surface morphology to enhance light extraction efficiency, thereby improving lumen output without requiring complex device structures or expensive materials
Solution Approach 2:
The patent utilizes porous or textured substrate surfaces with controlled pore sizes and distributions. These porous structures increase the surface area and create multiple interfaces for light extraction, improving optical efficiency and brightness while maintaining compatibility with standard manufacturing processes
2Productivity
If LED devices are made brighter and more efficient, then performance is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent applies preliminary chemical etching to the substrate surface before LED chip mounting. This pre-texturing of the substrate creates the optical enhancement features in advance, allowing subsequent assembly steps to proceed quickly without requiring complex post-processing or specialized manufacturing equipment
Solution Approach 2:
The patent replaces mechanical or complex fabrication methods with chemical etching processes to create the textured surface features. This substitution allows for simpler, faster manufacturing while achieving the same or better optical performance compared to conventional mechanical texturing methods
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 solution results in improved brightness, thermal management, and manufacturability of LED devices at a lower cost, making them more competitive and attractive for adoption.
Implementation Method 1
Surface features can improve optics of the LED device, for example, improving brightness, reflection, and/or light extraction associated with the device
Implementation Method 2
Allowing heat to dissipate directly from LED chips into the ceramic substrate can improve thermal properties of the device
Data Source
AI summary
Light emitter devices, such as light emitting diode (LED) devices and related methods are disclosed. A light emitter device includes a ceramic based substrate, at least one LED chip disposed on the substrate, and a filling material. The ceramic substrate can include one or more surface features. The filling material can be disposed over and/or within a portion of the one or more surface features. Surface features can include one or more pedestals, trenches, holes, indentions, depressions, waves, and/or convexly or concavely curved surfaces. Surface features can improve optics of the LED device, for example, improving brightness, reflection, and/or light extraction associated with the device. Related methods are disclosed.