Quantum dot module packaged by coating technology and its light emitting module

With the rapid advancement of technology, quantum dots have emerged as a key material in next-generation lighting and display technologies due to their exceptional properties such as long-lasting illumination, high color purity, and efficient light conversion. The U.S. Patent No. 9,577,127 B1 introduces an innovative quantum dot fluorescent microsphere structure. By combining this product with advanced coating techniques, a quantum dot module was developed, which led to the creation of a new type of lamp.

The quantum dot module, based on coating technology, as illustrated in FIG. 1, consists of a susceptor 1, a barrier film 2, and a carrier layer 3 containing quantum dots. The top surface of the susceptor is etched with a groove, and the quantum dot carrier layer is placed inside this groove. A barrier film is then applied to both the side and upper surfaces of the carrier layer. This design encapsulates the quantum dots within the carrier layer, ensuring they are fully protected by the susceptor and the barrier film, forming a secondary package. This dual-layer packaging effectively prevents the penetration of moisture and oxygen, significantly extending the lifespan of the quantum dots.

Furthermore, based on this quantum dot module, the company has developed a quantum dot light-emitting module, as shown in FIG. 2. This module includes a blue light chip 4, a phosphor layer 5, and the previously described quantum dot module, which is positioned above the phosphor layer 5 on the susceptor 1. The susceptor can be made from materials like sapphire, quartz, or glass, while the barrier film may consist of silicon monoxide, silicon dioxide, aluminum oxide, or parylene. The barrier film can be applied through spin-coating, vapor deposition, sputtering, or atomic layer deposition, ensuring a tight and protective layer that enhances the stability of the quantum dot material.

The quantum dot light-emitting module uses a sapphire substrate, a silicon oxide barrier film, and a silica-based carrier layer. The high refractive index of the silica carrier layer helps reduce light loss due to refraction at the interface, thereby improving light extraction efficiency. Additionally, the silica gel can be thoroughly mixed with the quantum dot material, offering initial protection against moisture and oxygen. However, since silica gel is hygroscopic, each carrier layer containing quantum dots is coated with the barrier film to completely isolate external moisture and oxygen. The SiO material, being denser than silica, provides a second layer of protection by preventing oxidation and further blocking moisture and oxygen, ensuring long-term performance and reliability of the quantum dot system.