LED Lead Frame Stacked Structure for Resin Adhesion
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Solution Overview
Problem
Existing light-emitting devices face challenges with adhesiveness between resin molded products and metal lead frames, leading to potential peeling off and disconnection issues.
Innovation Solution
A light-emitting device design featuring a lead frame with a stacked structure of multiple metal layers, including a penetration portion with stepped protrusions, and a resin frame body that fills and surrounds the penetration portion, enhancing adhesiveness and preventing peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin molded product is formed on a lead frame by insert molding, then the resin fills the cutout portion of the lead frame improving adhesiveness, but the contact area is limited to the thickness of the lead frame
Solution Approach 1:
The invention transitions from a two-dimensional contact surface (top surface of lead frame) to a three-dimensional contact structure by forming penetration portions that extend through the lead frame thickness. The resin fills these penetration portions, creating contact surfaces on both the upper and lower surfaces of the lead frame, effectively doubling the contact area and enhancing adhesiveness through multi-dimensional engagement.
Solution Approach 2:
The resin is nested within the penetration portions of the lead frame, with the resin filling the hollow spaces formed by the stacked metal plates. This nesting structure allows the resin to be surrounded by the lead frame on multiple sides, increasing the contact area and mechanical interlocking between the resin and lead frame.
Data Source
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AI summary
A light-emitting device 10 includes a lead frame 12, a frame body 11 having an opening portion 20 and formed integrally with the lead frame 12, and an LED 28 that is connected to leads 12a and 12b of the lead frame 12 and is disposed within the opening portion 20. The lead frame 12 has a stacked structure including an upper second layer metal plate 122 and a lower third layer metal plate 123, and a penetration portion 125 penetrates the stacked structure in an up-down direction. The second layer metal plate 122 protrudes into the penetration portion 125 from the third layer metal plate 123 to form a step. A resin of the frame body 11 fills the penetration portion 125.