Wavelength-Conversion Covering Member for Thin LED Light Extraction
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Solution Overview
Problem
Conventional light emitting devices are not thin enough for advanced applications, requiring a method to manufacture thinner devices with improved light extraction efficiency and reduced variance in light distribution properties.
Innovation Solution
A method involving a first light-reflective member with through-holes, a light-transmissive resin containing a wavelength-conversion material predominantly distributed on one side, and a second light-reflective member covering the lateral surfaces, allowing for thinning of the device while maintaining the wavelength-conversion material's content and improving light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the light emitting device is thinned to reduce overall thickness, then the device thickness is reduced, but the light extraction efficiency deteriorates
Solution Approach 1:
The patent applies local quality by creating an asymmetric distribution of wavelength-conversion material within the light-transmissive resin, concentrating it predominantly on one side of the through-hole. This localized concentration optimizes light extraction efficiency at the interface with the light-emitting element while maintaining the overall thin profile of the device, thus resolving the contradiction between thinning and light extraction performance.
2Stability of the object's composition
If the wavelength-conversion material is uniformly distributed throughout the light-transmissive resin, then the light distribution is homogeneous, but the light extraction efficiency and variance in light distribution properties increase
Solution Approach 1:
The patent employs asymmetry by deliberately creating a non-uniform distribution of wavelength-conversion material within the light-transmissive resin. The material is concentrated predominantly on one side of the through-hole rather than being uniformly distributed, which optimizes light extraction efficiency while controlling variance in light distribution properties.
3Strength
If a plate-shaped optical member with an outer frame is used as in conventional designs, then the structural integrity is maintained, but the device cannot be sufficiently thinned
Solution Approach 1:
The patent applies the extraction principle by removing the conventional outer frame structure from the plate-shaped optical member. This extraction allows the device to be sufficiently thinned while the essential light-guiding and wavelength-conversion functions are preserved through the optimized asymmetric distribution of wavelength-conversion material within the remaining light-transmissive resin structure.
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 method enables the production of thinner light emitting devices with reduced variance in light distribution properties and enhanced light extraction efficiency, addressing the limitations of conventional devices.
Implementation Method 1
a light-transmissive resin containing a wavelength-conversion material predominantly distributed on one side of one opening of the through-hole within the light-transmissive resin
Data Source
AI summary
A method of manufacturing a covering member includes: providing a first light-reflective member comprising a through-hole, the through-hole having first and second openings; arranging a light-transmissive resin containing a wavelength-conversion material within the through-hole; distributing the wavelength-conversion material predominantly on a side of the first opening of the through-hole within the light-transmissive resin; and after the step of distributing the wavelength-conversion material, removing a portion of the light-transmissive resin from a side of the second opening of the through-hole.