Vertical AC LED Heat Dissipation and Transformer Elimination
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Solution Overview
Problem
Traditional LEDs require a transformer for DC-AC conversion, leading to energy loss and increased costs, whereas AC-LEDs without transformers are more energy-efficient but face challenges in heat dissipation and electrode shading.
Innovation Solution
A vertical AC LED structure with a conductive substrate, parallel LEDs, and a specific fabrication method that includes forming insulating and conductive structures for efficient heat dissipation and reduced material costs, eliminating the need for a transformer and improving light-emitting performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional LED structure with transformer is used, then DC-AC conversion is achieved, but energy loss increases and usage cost increases
Solution Approach 1:
The patent inverts the conventional LED approach by designing the LED chip itself to operate directly with AC power instead of requiring external DC-AC conversion. The vertical AC LED structure with alternating current injection enables the device to function natively with AC power supply, eliminating the transformer and associated energy losses.
Solution Approach 2:
The patent extracts and removes the transformer component from the LED system entirely. By designing the LED to accept AC power directly, the external DC-AC conversion device is eliminated, reducing both energy loss and usage cost while simplifying the overall system.
2Temperature
If vertical AC LED structure is used, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent transitions from a horizontal/lateral LED structure to a vertical configuration, utilizing the vertical dimension to improve heat dissipation pathways. The vertical arrangement allows heat to conduct more efficiently from the active region through the substrate, addressing thermal management challenges while maintaining a compact form factor.
Solution Approach 2:
The vertical AC LED structure is segmented into distinct functional layers including the active region, contact structures, and substrate regions with different electrical properties. This segmentation allows optimized heat dissipation pathways and electrical isolation while managing the inherent structural complexity through organized functional zones.
3Ease of manufacture
If AC LED without transformer is used, then cost is reduced and space is saved, but heat dissipation becomes challenging
Solution Approach 1:
The patent changes key structural parameters by adopting a vertical configuration with specific layer arrangements and contact geometries. These parameter changes optimize both the thermal conduction pathways and electrical characteristics, enabling effective heat dissipation in the transformerless AC LED design.
Solution Approach 2:
The vertical AC LED employs composite material structures with different thermal and electrical properties in various layers. The substrate and contact structures utilize materials optimized for thermal conduction while maintaining electrical functionality, resolving the heat dissipation challenge in the simplified AC LED design.
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 vertical AC LED design enhances heat dissipation, reduces material costs, and improves light-emitting efficiency by eliminating the need for a transformer, making it more competitive and energy-efficient compared to traditional LEDs.
Implementation Method 1
a conductive substrate; a light-emitting module on the conductive substrate
Implementation Method 2
an ohmic contact is formed between the second semiconductor layer of the second LED and the conductive substrate
Implementation Method 3
two horizontally arranged in parallel and mutually-isolated LEDs, wherein the first and second LEDs include a first semiconductor layer, a light-emitting layer and a second semiconductor layer
Data Source
AI summary
The present invention discloses a vertical AC LED element and fabrication method thereof, wherein the vertical AC LED element comprises a conductive substrate (102); a light-emitting module on the conductive substrate (102), including two horizontally arranged in parallel and mutually-isolated LEDs; wherein the first and second LEDs include a first semiconductor layer (111), a light-emitting layer (112) and a second semiconductor layer (113) from top down; a first insulating layer (131) is arranged between the second semiconductor layer (113) of the first LED and the conductive substrate (102) for mutual isolation; an ohmic contact is formed between the second semiconductor layer (113) of the second LED and the conductive substrate (102); a first conductive structure that connects the first semiconductor layer (111) of the first LED, the second semiconductor layer (113) of the second LED and the conductive substrate (102); and a second conductive structure that connects the second semiconductor layer (113) of the first LED and the first semiconductor layer (111) of the second LED.