LED Package Lead Frame Segmentation for Uniform Light Distribution
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Solution Overview
Problem
Existing light emitting device packages face challenges in achieving optimal light distribution and brightness due to electrical shorts and non-uniform light absorption by insulating layers, which affect the overall efficiency and reliability of the lighting system.
Innovation Solution
The design incorporates a light emitting device package with a first and second lead frame separated by a separation part and a through part, both with irregular curved shapes, to ensure even light distribution, and includes a lens and resin layer with phosphors to enhance light characteristics, while also using concave parts and insulating layers to improve structural stability and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional lead frame structure is used without separation part and through part, then the device complexity is reduced, but electrical shorts occur and light distribution becomes non-uniform
Solution Approach 1:
The lead frame is divided into multiple separate components including a first lead frame, a second lead frame, a separation part, and a through part. This segmentation prevents electrical shorts between different lead frames while maintaining reliable electrical connections to the light emitting device, resolving the contradiction between reliability and complexity.
Solution Approach 2:
The separation part and through part act as intermediary elements between the first and second lead frames. These intermediaries provide physical separation to prevent electrical shorts while allowing the lead frames to maintain their functional roles, thus improving reliability without excessive complexity increase.
2Reliability
If insulating layers are used to separate lead frames, then electrical shorts are prevented, but light absorption becomes non-uniform affecting brightness
Solution Approach 1:
The separation part and through part are designed with curved cross-sections instead of flat insulating layers. This curvature optimizes light distribution by reducing non-uniform light absorption, while still maintaining the electrical insulation function between lead frames, thus resolving the contradiction between insulation reliability and light distribution uniformity.
Solution Approach 2:
The geometric parameters of the separation part and through part are optimized, specifically using curved cross-sections with adjusted radii and shapes. This parameter change improves light transmission uniformity while maintaining electrical insulation, addressing the contradiction between insulation effectiveness and optical performance.
3Use of energy by moving object
If the width of through part is increased to improve light distribution, then light efficiency improves, but the distance between through part and light emitting device becomes unbalanced
Solution Approach 1:
The width of the through part is optimized within a specific range (20-40 μm) to balance light distribution efficiency with structural symmetry. This parameter optimization ensures that light efficiency is improved while maintaining balanced distances between the through part and light emitting device, resolving the contradiction between energy efficiency and manufacturing precision.
4Illumination intensity
If irregular curved shapes are used for separation part and through part, then light distribution uniformity improves, but manufacturing complexity increases
Solution Approach 1:
Regular curved shapes (circular or elliptical cross-sections) are used for the separation part and through part instead of complex irregular shapes. This design achieves uniform light distribution through geometric optimization while maintaining ease of manufacture, as these regular curves can be easily formed using conventional fabrication processes, resolving the contradiction between optical performance and manufacturing 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 configuration improves light efficiency, reduces brightness loss, and enhances the reliability and sealing of the lighting system by ensuring uniform light distribution and effective heat dissipation, while minimizing thermal stress and color deviation.
Implementation Method 1
a resin layer on the light emitting device, disposed on the second lead frame and including phosphors
Data Source
AI summary
Disclosed are a light emitting device package and a lighting system including the same. The light emitting device package includes a first lead frame and a second lead frame disposed on an insulating layer and electrically separated from each other by a separation part, and a light emitting device disposed on the second lead frame and electrically connected to the first lead frame, and the second lead frame includes a through part disposed opposite to the separation part such that the light emitting device is located therebetween.