LED Carrier Reflective Shielding Against Light Degradation
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Solution Overview
Problem
Conventional LED packages face issues with the incorrect positioning and detachment of reflecting members due to adhesive degradation caused by direct exposure to LED light, leading to instability in the reflector's attachment.
Innovation Solution
An LED carrier design featuring a conductive layer with a bonding portion and an extending portion, where the adhesive layer covers the extending portion and exposes the bonding portion, and includes a hook portion that engages with the reflector's corner to secure it firmly, while the elevated bonding portion protects the adhesive from light exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reflecting member is mounted on the substrate using adhesives, then the reflecting member can be attached to the substrate, but the adhesive degrades due to direct exposure to LED light causing detachment
Solution Approach 1:
The conductive layer is divided into two distinct portions: a bonding portion that directly contacts the LED chip and an extending portion that supports the adhesive layer. This segmentation allows the adhesive to be positioned only on the extending portion, shielding it from direct light exposure while maintaining its attachment function.
Solution Approach 2:
The extending portion of the conductive layer acts as an intermediary barrier between the LED chip (light source) and the adhesive layer. It blocks direct light exposure to the adhesive while still allowing the adhesive to fulfill its bonding function, thereby preventing adhesive degradation.
2Reliability
If the reflecting member is mounted using adhesives, then the reflecting member can be attached, but incorrect positioning occurs due to inadvertent shifting before adhesive hardening
Solution Approach 1:
The adhesive layer is pre-configured with a hook portion that engages with the corner of the reflector before the adhesive hardens. This preliminary engagement action secures the reflector in the correct position, preventing inadvertent shifting during the hardening process.
Solution Approach 2:
The hook portion of the adhesive layer automatically engages with the corner of the reflector, providing self-positioning and self-securing functionality. This eliminates the need for complex external positioning mechanisms and prevents shifting without additional control steps.
3Ease of manufacture
If the adhesive layer is directly exposed to LED light, then the adhesive can be applied simply, but the adhesive degrades and the reflector detaches
Solution Approach 1:
The conductive layer is segmented into a bonding portion and an extending portion, creating a natural shield that protects the adhesive layer from direct light exposure. This segmentation maintains manufacturing simplicity while significantly improving adhesive durability by preventing light-induced degradation.
Data Source
AI summary
A LED carrier includes a substrate, a conductive layer, an adhesive layer, and a reflector. The conductive layer is disposed on the substrate, and has a bonding portion and an extending portion. The bonding portion has a top surface higher than a top surface of the extending portion. The adhesive layer covers the extending portion of the conductive layer and exposes the bonding portion of the conductive layer. The reflector is disposed over the adhesive layer. The adhesive layer has a hook portion in contact with a corner of the reflector.