Wavelength Converting Layer with Particulate Spacers for Uniform Phosphor Distribution
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Solution Overview
Problem
Conventional semiconductor light-emitting devices with high-density phosphor wavelength converting layers face challenges in maintaining uniform thickness and color consistency, particularly when used in vehicle headlights, where a small light-emitting surface requires high light-emitting efficiency and uniform illumination across a wide area.
Innovation Solution
A semiconductor light-emitting device design featuring a thin and uniform wavelength converting layer with a high density of phosphor, supported by particulate spacers and a reflective material layer, which maintains a consistent thickness and enhances light-emitting efficiency by using a transparent plate and a reflective material layer to direct light effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a high-density phosphor wavelength converting layer is used to improve light-emitting efficiency, then the light-emitting efficiency is improved, but the thickness uniformity and color consistency deteriorate
Solution Approach 1:
The patent applies local quality by creating a wavelength converting layer with spatially varying phosphor distribution. The phosphor concentration is higher near the light-emitting chip and gradually decreases toward the outer regions, allowing efficient wavelength conversion near the source while maintaining uniform overall thickness and color consistency across the entire layer.
Solution Approach 2:
The patent utilizes parameter changes by varying the phosphor particle size distribution and concentration gradient within the wavelength converting layer. By controlling these parameters spatially, the invention achieves both high light-emitting efficiency and uniform thickness, resolving the contradiction between efficiency and manufacturing precision.
2Use of energy by moving object
If a high-density phosphor wavelength converting layer is used to improve light-emitting efficiency, then the light-emitting efficiency is improved, but the color consistency deteriorates
Solution Approach 1:
The patent applies local quality by creating a wavelength converting layer with spatially varying phosphor distribution. The phosphor concentration is higher near the light-emitting chip and gradually decreases toward the outer regions, allowing efficient wavelength conversion near the source while maintaining uniform overall thickness and color consistency across the entire layer.
Solution Approach 2:
The patent achieves equipotentiality by ensuring uniform color output across the entire wavelength converting layer despite varying phosphor concentrations. The gradient distribution is carefully designed so that the overall color appearance remains consistent, creating an equipotential color field that eliminates color variability.
3Manufacturing precision
If a thin wavelength converting layer is used to maintain uniform thickness, then the thickness uniformity is improved, but the phosphor density must be increased to maintain conversion efficiency
Solution Approach 1:
The patent utilizes parameter changes by varying the phosphor particle size distribution and concentration gradient within the wavelength converting layer. By controlling these parameters spatially, the invention achieves both high light-emitting efficiency and uniform thickness, resolving the contradiction between efficiency and manufacturing precision.
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 solution achieves high light-emitting efficiency and uniform color emission from a small light-emitting surface, reducing color variability and manufacturing complexity, while allowing for consistent production across different lots.
Implementation Method 1
a wavelength converting layer 13 disposed between the bottom surface of the transparent plate 14 and at least a side surface of the light-emitting chip 11 so that a side surface 130 thereof extends from the side surface of the light-emitting chip 11 toward the bottom surface of the transparent plate 14, and including at least one phosphor 13a
Implementation Method 2
a reflective material layer to direct light effectively
Data Source
AI summary
A semiconductor light-emitting device and a method for manufacturing the same can include a wavelength converting layer located on at least one semiconductor light-emitting chip in order to emit various colored lights including white light. The semiconductor light-emitting device can include a base board, the chip mounted on the base board and a transparent plate disposed on the wavelength converting layer including a spacer and a phosphor having a high density. The wavelength converting layer can be formed in a thin uniform thickness between the transparent plate and a top surface of the chip using the spacer so as to extend toward the transparent plate. The semiconductor light-emitting device can be configured to improve light-emitting efficiency of the chip by using the thin wavelength converting layer including the phosphor having a high density, and therefore can emit a wavelength-converted light having a high light-emitting efficiency from a small light-emitting surface.