Method for manufacturing wavelength conversion member having depressed portion and light-emitting device including the same
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Solution Overview
Problem
Existing methods for manufacturing wavelength conversion members with depressed portions, such as etching and mechanical machining, face challenges in achieving precise shapes due to material differences and tool wear, making it difficult to obtain intended shapes, especially when using phosphor layers with mixtures of materials.
Innovation Solution
A method involving the use of a pulsed laser beam to form continuous machining marks at different processing depths, allowing for the creation of inclined surfaces in wavelength conversion members with a phosphor and light-transmissive portions, enabling the formation of desired depressed portions with improved precision and reduced material differences in etching rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If etching with lithography technique is used to form inclined surface structures, then the phosphor layer can be processed, but differences in etching rates between materials make it difficult to obtain the intended shape
Solution Approach 1:
The patent replaces the mechanical etching process with a laser-based processing system. The laser beam irradiates the wavelength conversion member to form depressed portions with inclined surfaces, eliminating the problem of differential etching rates between phosphor and other materials that plagues conventional lithography etching methods.
Solution Approach 2:
The patent employs multiple laser processing parameters including pulse width, repetition frequency, scanning speed, and irradiation intensity to precisely control the formation of depressed portions. By adjusting these parameters, the system achieves accurate shape control regardless of material composition differences, resolving the precision issue with conventional etching.
2Ease of manufacture
If mechanical machining using a blade is used to form depressed portions, then the phosphor layer can be machined, but the blade wear causes the shape to change as machining progresses
Solution Approach 1:
The patent replaces mechanical blade machining with a non-contact laser processing system. This eliminates tool wear entirely, as the laser beam does not physically contact the workpiece, thereby maintaining consistent depressed portion shapes throughout the machining process regardless of processing duration.
Solution Approach 2:
The laser processing system is self-regulating, with the laser beam automatically maintaining its properties without degradation. The system does not require tool replacement or recalibration like mechanical blades, ensuring consistent shaping performance throughout operation.
3Manufacturing precision
If conventional processing methods are used, then material differences in etching rates affect shape accuracy, but laser processing with multiple scanning passes enables precise shape formation
Solution Approach 1:
The patent divides the laser processing into multiple scanning passes with different parameters. Each pass contributes to forming the final depressed portion shape, allowing precise control over the inclined surfaces and depth while managing the complexity through systematic parameter variation.
Solution Approach 2:
The patent employs periodic laser pulsing with controlled repetition frequencies to process the wavelength conversion member. This periodic action allows heat management and precise material removal, achieving high precision shapes while the systematic parameter control manages the overall process complexity.
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 approach enables the precise formation of depressed portions with desired shapes in wavelength conversion members, reducing the risk of material breakage and improving light extraction efficiency in light-emitting devices by controlling light reflection and extraction.
Implementation Method 1
forming, in the wavelength conversion member, at least one depressed portion each having an inclined surface inclined with respect to the upper surface by irradiating the wavelength conversion member with a pulsed laser beam from above
Implementation Method 2
forming, in the wavelength conversion member, at least one depressed portion each having an inclined surface inclined with respect to the upper surface by irradiating the wavelength conversion member with a pulsed laser beam from above more than once to form a plurality of continuous machining marks at different processing depths
Data Source
AI summary
A wavelength conversion member manufacturing method includes providing a wavelength conversion member having an upper surface, and forming, in the wavelength conversion member, at least one depressed portion having an inclined surface inclined with respect to the upper surface by irradiating the wavelength conversion member with a pulsed laser beam from above. The forming of the at least one depressed portion includes performing a set of scanning more than once at different processing depths in regions overlapping each other in a top view, the set of scanning includes performing scanning with the pulsed laser beam along a first direction more than once at irradiation positions shifted in a second direction perpendicular to the first direction in the top view, and the performing of the scanning includes applying the pulsed laser beam at a fixed processing depth.