LED Base Strength via Bent Lead Separation
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Solution Overview
Problem
Light emitting devices are prone to damage from external impact or stress, leading to reliability issues due to the vulnerability of the base between the leads, which can cause disconnection of the wire and failure of the device, while maintaining luminous efficacy and heat dissipation efficiency is compromised by reducing the cavity area or increasing lead separation.
Innovation Solution
A light emitting device design featuring leads with protrusions and indentations on their side surfaces, along with chamfered portions, where the separation region between the leads has a bent shape, enhancing the strength of the base and preventing crack propagation, and a thickened reflector to maintain luminous intensity without increasing separation distance or altering other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the cavity area is increased to improve luminous efficacy, then luminous efficacy is improved, but the base between the leads becomes thinner and weaker, reducing strength and reliability
Solution Approach 1:
The separation region between the first and second leads is designed with a bent shape rather than a straight line, creating a curved structural configuration. This curvature distributes stress more effectively and prevents crack propagation while maintaining adequate base thickness for strength, thereby resolving the contradiction between luminous efficacy and base strength
Solution Approach 2:
The lead structure incorporates localized features including protrusions and indentations at specific positions along the leads. These local structural modifications reinforce the base material in critical areas without affecting the overall cavity area, enabling the base to maintain both sufficient strength and adequate luminous efficacy
2Temperature
If the separation distance between the leads is increased to improve heat dissipation efficiency, then heat dissipation efficiency is improved, but the overall device size increases and structural compactness deteriorates
Solution Approach 1:
The bent separation region creates an optimized thermal pathway that efficiently conducts heat from the LED chip through the base to the leads. The curved geometry provides adequate thermal dissipation distance without requiring a linear increase in lead separation, thereby maintaining structural compactness while achieving effective heat dissipation
3Loss of energy
If the lateral thickness of the reflector is reduced to increase the cavity area, then luminous efficacy is improved, but the overall structural strength and durability are reduced
Solution Approach 1:
The lead structure incorporates localized features including protrusions and indentations at specific positions along the leads. These local structural modifications reinforce the base material in critical areas without affecting the overall cavity area, enabling the base to maintain both sufficient strength and adequate luminous efficacy
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5A
AI summary
Disclosed is a light emitting device. The light emitting device comprises: a first lead and a second lead which are spaced apart from each other; a body part comprising a base, a reflector, and a cavity; and a light emitting diode which is disposed in the cavity, wherein the first lead includes a first bottom lead and a first top lead located on the first bottom lead, and the second lead includes a second bottom lead and a second top lead located on the second bottom lead, and wherein the shape of a spaced-apart region of the first top lead and the second top lead is different from the shape of a spaced-apart region of the first bottom lead and the second bottom lead, the spaced-apart region of the first top lead and the second top lead having a shape which bends at least one time.