Light Emitting Device Electroconductive Protrusions
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Solution Overview
Problem
Conventional light emitting devices face challenges in achieving adequate heat dissipation while maintaining a thin and compact form, and they often suffer from mechanical instability during mounting and use due to inadequate adhesion of electroconductive layers to the translucent insulating member.
Innovation Solution
A light emitting device design featuring electroconductive layers with protrusions on their side faces, which are rounded at the upper edges, and a translucent insulating member with these layers as its bottom surface, along with a manufacturing method involving the formation of electroconductive layers on a metal matrix material, followed by the integration of a light emitting element and sealing with a translucent insulating member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the insulating substrate is made thinner to shorten the heat dissipation path, then heat dissipation is improved, but the mechanical strength of the electroconductive member becomes insufficient
Solution Approach 1:
The patent employs a composite structure consisting of a resin layer combined with a metal foil layer. The resin provides electrical insulation and structural support, while the metal foil embedded within the resin serves as the electroconductive member for heat dissipation and electrical connection. This composite approach allows the electroconductive member to maintain mechanical strength even when the overall substrate thickness is reduced for improved heat dissipation.
2Ease of manufacture
If electrodes are embedded in resin with side faces parallel to embedding direction, then manufacturing is simplified, but adhesion between electrode and resin is insufficient causing separation during mounting
Solution Approach 1:
The patent introduces protrusions on the side faces of the electroconductive layers, with upper edges that are rounded off. This curved geometry creates mechanical interlocking between the electrode and the surrounding resin, significantly improving adhesion. The rounded edges prevent stress concentration and reduce the likelihood of separation during mounting and use, while still allowing for relatively simple manufacturing processes.
3Illumination intensity
If the translucent insulating member is made without filler to maintain translucency, then light takeoff efficiency is improved, but mechanical strength is reduced making electrode separation more likely
Solution Approach 1:
The patent uses a composite structure where a metal foil layer is embedded within the translucent resin. The metal foil provides the necessary mechanical reinforcement to the insulating member without interfering with light transmission. This allows the device to maintain high light takeoff efficiency while the embedded metal structure provides the mechanical strength needed to prevent electrode separation during mounting and use.
Data Source
AI summary
A light emitting device, comprises a light emitting element, a plurality of electroconductive layers on which said light emitting element is mounted or which are electrically connected to the light emitting element, and a translucent insulating member that seals the light emitting element and has the electroconductive layers as its bottom surface, wherein the electroconductive layers have a protrusion on part of their side faces, and the upper edges of the protrusion is rounded off.