Light-Transmissive Member Corner Pressing for Peeling-Resistant LEDs
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Solution Overview
Problem
Existing light-emitting device manufacturing methods lack reliability due to inadequate adhesion and peeling issues between light-transmissive members and substrates, leading to potential device failure.
Innovation Solution
A method involving a light-transmissive member with a rectangular shape, initially uncured, is disposed over light-emitting elements and pressed at corner regions to ensure contact with the substrate outside the element placement area, followed by curing, enhancing adhesion and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the light-transmissive member is disposed to cover the light-emitting elements without pressing, then the manufacturing process is simple, but the adhesion between the light-transmissive member and substrate is insufficient leading to peeling issues
Solution Approach 1:
The pressing operation is performed on the uncured light-transmissive member before curing to pre-establish contact between the member and substrate. This preliminary mechanical action ensures proper positioning and initial adhesion before the curing process sets the final bonded state, preventing peeling issues that would occur without this intermediate pressing step
2Reliability
If the light-transmissive member is pressed at corner regions to contact the substrate, then adhesion is improved, but the manufacturing process becomes more complex
Solution Approach 1:
Instead of pressing the entire light-transmissive member uniformly, the pressing operation is applied locally only to the corner regions. This localized approach achieves sufficient adhesion by ensuring contact at critical anchor points while minimizing the overall complexity of the manufacturing process compared to full-surface pressing
3Reliability
If the light-transmissive member is pressed before curing, then adhesion is enhanced, but the processing time increases
Solution Approach 1:
The pressing operation is applied partially only to the corner regions of the light-transmissive member rather than the entire surface. This partial action achieves sufficient adhesion for reliable operation while minimizing the time required for the pressing step, as fewer regions need to be processed compared to full-surface pressing
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 approach significantly improves the adhesion between the light-transmissive member and the substrate, reducing peeling risks and resulting in a more reliable light-emitting device.
Implementation Method 1
pressing one or more corner regions of the light-transmissive member, such that a part of a lower surface of the light-transmissive member is in contact with the upper surface of the substrate outside the element placement region
Implementation Method 2
after said pressing the one or more corner regions, curing the light-transmissive member
Data Source
AI summary
A method for manufacturing the light-emitting device includes: preparing a substrate including a plurality of light-emitting elements disposed in an element placement region of the substrate that is on an upper surface; disposing a light-transmissive member to cover the plurality of light-emitting elements, the light-transmissive member having a rectangular shape in a plan view and being uncured, and pressing one or more corner regions of the light-transmissive member, such that a part of a lower surface of the light-transmissive member is in contact with the upper surface of the substrate outside the element placement region; and curing the light-transmissive member after pressing the one or more corner regions.