Integrated Mold for LED Light Extraction and Covering
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Solution Overview
Problem
Existing light emitting device manufacturing methods lack efficiency in forming light-transmissive members and covering structures, leading to variations in shape and reduced visibility due to the need for separate steps in forming and singulating components.
Innovation Solution
A method involving a mold with recesses and projections to simultaneously mount and cover light emitting elements with light-transmissive materials, forming covering members that cover both the elements and the mold's surfaces, allowing for integrated formation of light-transmissive members and improved visibility without requiring singulated and cured components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate steps are used for forming light-transmissive members and covering structures, then manufacturing precision can be maintained, but productivity decreases and manufacturing time increases
Solution Approach 1:
The patent combines the formation of light-transmissive members and covering structures into a single integrated molding step. The mold includes a light-transmissive member forming cavity and a covering structure forming cavity that are filled with different materials simultaneously, eliminating the need for separate forming and singulation steps while maintaining shape consistency through the mold's precise cavity design
Solution Approach 2:
The mold is segmented into multiple cavities with different functions - a light-transmissive member forming cavity and a covering structure forming cavity. This allows different materials to be molded separately in their designated cavities while being formed simultaneously in one molding cycle, resolving the contradiction between integration and precision
2Productivity
If integrated molding is used to form light-transmissive members and covering structures, then productivity increases, but device complexity increases
Solution Approach 1:
The mold is designed as a multi-functional device that simultaneously performs multiple functions: forming light-transmissive members, forming covering structures, and providing structural support during the molding process. The covering structure forming cavity serves both as a mold cavity and as the future covering structure that will protect the LED, reducing the need for additional components
3Loss of time
If separate steps are used for forming and singulating components, then manufacturing precision is maintained, but loss of time increases
Solution Approach 1:
The mold is designed with preliminary structural features - projections on the light-transmissive member forming cavity bottom and corresponding recesses in the covering structure forming cavity - that pre-establish the mounting positions and interfaces. This preliminary design ensures that when materials are molded, the components automatically achieve correct positioning and alignment without requiring subsequent singulation or positioning steps
Data Source
AI summary
A method of manufacturing a light emitting device include providing a mold with a mold recess having a bottom and an inner peripheral surface that is connected to the bottom. The bottom includes a bottom projection and a bottom recess surrounding the bottom projection to define the bottom projection that has a projection top surface and a projection peripheral surface opposing the inner peripheral surface. A light emitting element is mounted on the bottom projection such that a light extraction surface of the light emitting element faces the projection top surface and such that an outer peripheral surface of the light emitting element opposes the inner peripheral surface of the mold recess. A covering material is provided in the mold recess to cover the inner peripheral surface of the mold recess, the outer peripheral surface of the light emitting element, and the projection peripheral surface.