Wavelength Conversion Member Complex with Concave Joining Zone
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Solution Overview
Problem
Conventional light emitting devices face challenges in heat dissipation and light output efficiency due to the formation of concave portions in phosphor or heat dissipation members, which can compromise the strength of the phosphor layer and increase manufacturing complexity and costs, and the use of adhesives can diminish heat dissipation and light output.
Innovation Solution
A wavelength conversion member complex is designed with a support having through-holes and a concave portion on its lower surface, where the phosphor member is disposed within the through-hole, and a joining material is placed in the concave portion, allowing direct contact between the heat dissipation member and the support, thereby avoiding the interposition of joining material between the phosphor and heat dissipation members, enhancing heat dissipation and light emission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If concave portions are formed in the phosphor layer to join the heat dissipation member, then the joining strength is improved, but the strength of the phosphor layer is compromised
Solution Approach 1:
The invention separates the joining function from the phosphor layer by forming concave portions in the support structure instead. The support is divided into a light-transmitting portion (holding phosphor) and a joining portion (with concave portions for adhesive), allowing independent optimization of both functions without compromising phosphor layer integrity
Solution Approach 2:
The support structure acts as an intermediary between the phosphor layer and heat dissipation member. It provides dedicated joining portions that mediate the connection, preventing direct contact between adhesive and phosphor while ensuring secure mechanical and thermal connection
2Strength
If concave portions are formed in the heat dissipation member, then the joining strength is improved, but the work complexity increases and cost rises
Solution Approach 1:
The concave portions are pre-formed in the support structure during manufacturing, before assembly with the heat dissipation member. This preliminary preparation simplifies the overall manufacturing process by eliminating the need for complex post-assembly operations on the heat dissipation member
3Strength
If adhesive is disposed between the phosphor layer and heat dissipation member, then the joining strength is improved, but heat dissipation efficiency is diminished
Solution Approach 1:
The support is segmented into functional zones: light-transmitting portions that maintain optical contact with phosphor, and joining portions with concave portions that hold adhesive for thermal contact with heat dissipation member. This segmentation allows adhesive to be positioned where it provides mechanical bonding without interfering with thermal pathways
Solution Approach 2:
The joining portions of the support act as intermediaries that hold the adhesive in controlled positions, ensuring the adhesive bonds the support to the heat dissipation member without creating thermal barriers between the phosphor and heat dissipation pathways
4Strength
If adhesive is disposed between phosphor layer and heat dissipation member, then the joining strength is improved, but light output is reduced
Solution Approach 1:
The support is divided into light-transmitting portions (free of adhesive for optimal light transmission) and joining portions (with adhesive for mechanical bonding). This spatial segmentation ensures adhesive does not interfere with optical performance while maintaining structural integrity
Solution Approach 2:
The joining portions serve as intermediaries that isolate the adhesive from the optical path. The adhesive is confined to non-light-transmitting zones, allowing it to perform mechanical bonding functions without absorbing or scattering light that passes through the light-transmitting portions
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 enables efficient heat dissipation and maintains high light emission reliability by preventing light absorption and material deterioration, reducing the risk of separation between the wavelength conversion and heat dissipation members.
Implementation Method 1
a phosphor member (12) disposed in the through-hole (11c) and including a phosphor
Implementation Method 2
the heat dissipation member (15) is disposed under the joining material (14) and the phosphor member (12), and has an upper surface (15a) in contact with the lower surface (14b) of the joining material (14)
Data Source
AI summary
A wavelength conversion member complex includes a wavelength conversion member, a joining material, and a heat dissipation member. The wavelength conversion member includes a support and a phosphor member. The support defines a through-hole extending from an upper surface to a lower surface. The support has a concave portion on the lower surface around the through-hole. The concave portion is spaced apart from the through-hole. The phosphor member is disposed in the through-hole and includes a phosphor. The lower surface of the phosphor member is continuous with the lower surface of the support. The joining material is disposed in the concave portion, and has a lower surface that is flush with the lower surface of the support. The heat dissipation member is disposed under the joining material and the phosphor member, and has an upper surface in contact with the lower surface of the joining material.