Leadframe Light Emitters: Molding Support and Brightness
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Solution Overview
Problem
Conventional leadframe-based light emitter components lack structural support during molding and inefficiently utilize spacing, leading to suboptimal brightness and manufacturability.
Innovation Solution
A leadframe-based light emitter component design that includes a leadframe element with electrical devices attached before molding, where the leadframe and devices are partially or fully encapsulated within a molded body, providing structural support and concealing the electrical components from the LED emission profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If leadframe elements are molded without structural support, then manufacturing simplicity is maintained, but molding process stability deteriorates
Solution Approach 1:
The patent applies preliminary action by attaching electrical devices to the leadframe elements before the molding process. This pre-attachment provides structural support to the leadframe during molding, ensuring process stability without compromising manufacturing simplicity. The electrical devices serve as preliminary structural reinforcements that prevent leadframe deformation during the molding operation.
2Ease of manufacture
If spacing within the component is not optimized, then manufacturing simplicity is maintained, but brightness and light extraction deteriorate
Solution Approach 1:
The patent applies local quality by optimizing the spacing of leadframe elements in specific regions where light extraction is critical. The leadframe elements are positioned with precise spacing to maximize light extraction efficiency and brightness in the emission area, while maintaining standard manufacturing processes elsewhere in the component. This localized optimization allows improved optical performance without requiring complete redesign of the manufacturing process.
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 design enhances manufacturability, increases light extraction and brightness, and optimizes space utilization within the component.
Implementation Method 1
a molded body, such as for example a molded cup, encasing portions of the leadframe element and at least part or all of the electrical device connected thereto
Data Source
AI summary
Leadframe based light emitter components and methods are provided. In some aspects, a leadframe based light emitter component includes a leadframe element, an electrical device connected to a portion of the leadframe element, and a molded cup encasing portions of the leadframe element and the electrical device connected thereto. A method of providing a leadframe based light emitter component includes providing a leadframe element, connecting an electrical device to a portion of the leadframe element, and molding a body over portions of the leadframe element and the electrical device.