Wavelength Conversion Member Via Electrode Light Leakage
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Solution Overview
Problem
Conventional wavelength conversion members for light-emitting devices face issues with unconverted light leakage and contamination of electrode bonding pads due to gaps and precise alignment challenges, as well as positional limitations for electrode placement.
Innovation Solution
A wavelength conversion member with a wavelength converting plate and via electrodes made of conductive material, where the plate has through-holes conforming to the electrode, and a metal joining portion between the electrode and via electrode to prevent light leakage and contamination, allowing for flexible electrode placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a through-hole is formed in the wavelength conversion member to accommodate the electrode, then the electrode can be securely positioned, but gaps may be produced between the wavelength conversion member and the electrode causing unconverted light leakage
Solution Approach 1:
A resin layer is introduced as an intermediary material between the wavelength conversion member and the electrode. This resin layer fills the gap formed by the through-hole structure, preventing unconverted light from leaking through while maintaining the electrode's secure positioning. The resin acts as a mediator that resolves the conflict between needing a through-hole for positioning and avoiding gaps for light leakage prevention.
2Strength
If adhesive material is applied to adhere the wavelength conversion member to the light emitting element, then bonding is achieved, but the adhesive may stick to the upper surface of the electrode contaminating the bonding pad
Solution Approach 1:
The resin layer serves as a protective intermediary between the adhesive material and the electrode's upper surface. When adhesive is applied to bond the wavelength conversion member to the light emitting element, the resin layer prevents the adhesive from contacting and contaminating the bonding pad on the electrode, thus maintaining bonding pad cleanliness while achieving strong bonding.
3Object-generated harmful factors
If the wavelength conversion member encircles the entire outer circumference of the electrode, then light leakage is prevented, but the electrode cannot be arranged at the outer circumferential end-side of the light-emitting element
Solution Approach 1:
The resin layer acts as a light-blocking intermediary that compensates for the wavelength conversion member not encircling the entire electrode circumference. By filling the gap between the wavelength conversion member and the electrode with light-curing resin, the structure prevents light leakage even when the electrode is positioned at the outer circumferential end, thus enabling flexible electrode placement while maintaining light leakage prevention.
4Manufacturing precision
If multiple wavelength conversion members are engaged to form a through-hole, then the electrode can be held from both sides, but it is extremely difficult to engage the end portions precisely without producing gaps
Solution Approach 1:
The resin layer serves as a compensatory intermediary that fills gaps between engaged wavelength conversion members. This allows the end portions of multiple wavelength conversion members to be engaged without requiring extremely precise alignment, as the resin will fill any gaps that form, preventing light leakage while accommodating manufacturing tolerances.
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
Prevents unconverted light leakage and contamination of bonding pads, eliminating positional restrictions for electrode placement and improving manufacturing efficiency by directly integrating via electrodes within the wavelength conversion member.
Implementation Method 1
a wavelength conversion member for converting a wavelength of light emitted from a light-emitting element
Data Source
AI summary
Provided is a wavelength conversion member, a light emitting device, and a method of manufacturing the light emitting device, with which leakage of unconverted light and contamination of an upper surface of an electrode are prevented, and restriction on a position at which the electrode is to be provided on the light-emitting element is eliminated. The wavelength conversion member provided on a light extracting side of a light-emitting element having an electrode on the light extracting side and configured to convert a wavelength of outgoing light from the light-emitting element includes: a wavelength converting plate having a phosphor excited by the outgoing light, and a through-hole penetrating between a front surface and a back surface so as to correspond to the electrode; and a via electrode made of a conductive material filled in the through-hole, and having an upper surface exposed at the front surface of the wavelength converting plate.