LED Covering Member Electrode Layout Without Plating Masks
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Solution Overview
Problem
The existing methods for manufacturing light emitting devices require multiple steps, including the use of masks for forming plated electrodes, which increases complexity and inefficiency.
Innovation Solution
A method involving an intermediate member with light emitting elements and a covering member, where a metal layer is formed to cover the electrodes and then patterned using laser ablation to create external connection electrodes without the need for masks, simplifying the process and reducing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If masks are used for forming plated electrodes, then electrode formation is achieved, but the number of manufacturing steps increases
Solution Approach 1:
The patent replaces the mechanical mask-based electrode formation process with a direct plating process where the covering member itself serves as the electrode structure. This substitution eliminates the need for separate masks and reduces manufacturing steps while maintaining electrode formation capability.
Solution Approach 2:
The covering member is designed to serve multiple functions: it provides structural coverage for the light emitting element and simultaneously functions as the electrode structure. This multi-functionality eliminates the need for separate electrode formation steps using masks, thereby reducing device complexity.
2Manufacturing precision
If multiple manufacturing steps are used, then precise electrode formation is achieved, but production efficiency decreases
Solution Approach 1:
The patent merges the covering member and electrode structure into a single integrated component. This consolidation allows electrode formation to occur simultaneously with the covering member fabrication process, maintaining manufacturing precision while significantly improving production efficiency by reducing the total number of steps.
3Volume of moving object
If small-sized light emitting devices are manufactured, then device size is reduced, but mounting difficulty increases
Solution Approach 1:
The patent extends the electrode structure laterally beyond the light emitting element boundaries in the planar dimension. This dimensional extension provides larger mounting surfaces for connection, making assembly easier despite the compact size of the light emitting element itself, thus resolving the contradiction between small device size and mounting ease.
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 approach allows for the efficient and simplified production of small-sized light emitting devices with larger external connection electrodes, facilitating easier mounting and reducing the risk of short-circuits during assembly.
Implementation Method 1
remove a portion of the metal layer by irradiating the metal layer with laser light to form a plurality of external connection electrodes
Data Source
AI summary
A light emitting device includes: a first light emitting element that comprises a pair of first electrodes; a second light emitting element that comprises a pair of second electrodes; a covering member that integrally covers the first and second light emitting elements such that lower surfaces of the pair of first electrodes and lower surfaces of the pair of second electrodes are exposed from a lower surface of the covering member; a pair of first external connection electrodes, each comprising: a first portion that covers the lower surface of a respective first electrode, and a second portion that covers a portion of the lower surface of the covering member; and a pair of second external connection electrodes, each comprising: a first portion that covers the lower surface of a respective second electrode, and a second portion that covers a portion of the lower surface of the covering member.