LED Contact Contour Matching for Conductive Adhesive Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In light-emitting diode (LED) manufacturing, the conductive material used to attach LEDs to carriers can flow during the curing process, causing the LEDs to shift and lose their precise positioning, leading to electrical misconnections and reduced device reliability.
Innovation Solution
The design incorporates contacts on the carrier with contours matching the electrodes, ensuring strong adhesion of the conductive material and preventing it from flowing to areas with lower adhesion strength, thus maintaining the LED's position and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive material is used to attach LED to carrier, then electrical connection is established, but the conductive material flows during curing process causing LED position shift
Solution Approach 1:
The contact structure is divided into two distinct parts: a contact body and a contact protrusion. The contact protrusion specifically engages with the electrode contour to prevent conductive material flow, while the contact body provides the electrical connection function. This segmentation allows each part to optimize its specific function without interference.
Solution Approach 2:
The contact protrusion is pre-formed with a contour that matches the electrode shape before the attachment process. This preliminary structuring creates a mechanical constraint that guides and restricts the conductive material during curing, preventing it from flowing in directions that would cause LED position shift, while still allowing proper electrical connection.
2Reliability
If conductive material is applied to attach LED, then electrical connection is achieved, but the material flows to areas with lower adhesion strength causing misalignment
Solution Approach 1:
The contact structure has non-uniform geometry with a contact protrusion that creates localized high adhesion zones. The protrusion's contour is specifically designed to match the electrode shape, creating localized areas of strong adhesion that anchor the conductive material in place during curing, preventing it from flowing to areas with lower adhesion strength.
3Strength
If contact structure is designed with contour matching electrode, then adhesion strength is improved, but device complexity increases
Solution Approach 1:
The contact structure features an asymmetric design where the contact protrusion has a specific contour that matches the electrode shape, while the rest of the contact body maintains a simpler form. This asymmetric approach concentrates the complexity only where needed (at the protrusion-electrode interface) to maximize adhesion, while keeping the overall structure relatively simple and manufacturable.
Data Source
AI summary
A light-emitting device includes a light-emitting element having a first electrode and a second electrode, a carrier, a first contact and a second contact. The first contact is arranged on the carrier and is electrically connected to the first electrode. The second contact is arranged on the carrier and is electrically connected to the second electrode. The first contact has a contour similar with that of the first electrode. The second contact has a contour similar with that of the second electrode.