Light Emitting Device Light-Shielding Frame Resin Placement
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Solution Overview
Problem
Existing methods for manufacturing light emitting devices with a light-shielding frame struggle to ensure the accurate and reliable placement of a resin member surrounding the light emitting element, which affects the luminance difference between the inside and outside of the light emission surface.
Innovation Solution
A method involving a first intermediate body with a substrate, light emitting element, protecting element, light transmissive member, and light-shielding frame, where a resin is applied between the light emitting element and the substrate, moving along the protecting element to form a cover member, and a second cover member is formed to cover the first cover member and lateral surfaces of the light-shielding frame, ensuring the resin is properly positioned and the luminance difference is enhanced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light-shielding frame is disposed around the light emitting surface to increase luminance difference, then the luminance difference between inside and outside is improved, but the resin member placement becomes difficult to confirm and control
Solution Approach 1:
The patent introduces a protecting element as an intermediary component that serves dual purposes: it protects the light emitting element and acts as a reference marker for resin member placement. The protecting element is positioned such that its relationship with the light-shielding frame provides a visual reference for confirming resin placement accuracy, thus resolving the contradiction between achieving high luminance difference and maintaining manufacturing precision.
Solution Approach 2:
The patent utilizes visual contrast and color differentiation between components (protecting element, light-shielding frame, resin member) to enable easy confirmation of resin placement. By designing components with distinguishable visual characteristics, the placement accuracy can be verified without complex inspection equipment, thereby maintaining manufacturing precision while achieving the desired luminance difference.
2Productivity
If the light-shielding frame is positioned to maximize light extraction efficiency, then the luminance difference is improved, but the inspection of resin member placement becomes more difficult
Solution Approach 1:
The protecting element serves as an intermediary reference that simplifies inspection. By positioning the protecting element in a specific relationship with the light-shielding frame and resin member, it creates a visual triangle or reference pattern that makes it easy to detect whether the resin member is properly placed, thus reducing inspection difficulty while maintaining high light extraction efficiency.
Solution Approach 2:
The patent performs preliminary positioning of the protecting element and design of the assembly structure before final resin application. This preliminary arrangement creates built-in visual references that automatically indicate correct resin placement, eliminating the need for complex post-application inspection processes and maintaining high productivity.
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 method allows for the easy and reliable placement of the resin member, increasing the luminance difference between the inside and outside of the light emission surface, thereby efficiently extracting light emitted by the light emitting element.
Implementation Method 1
disposing a first resin between the light emitting element and the substrate by applying the first resin on the substrate in a region outside of the portion of the protecting element exposed from the light-shielding frame in the top view such that the first resin moves toward the light emitting element along the protecting element
Data Source
AI summary
A method of manufacturing a light emitting device includes: providing a first intermediate body including a substrate, first bonding members, a second bonding member, a light emitting element, a protecting element, a light transmissive member bonded to the light emitting element, and a light-shielding frame surrounding the light transmissive member in a top view, a portion of an outer periphery of the light-shielding frame being located above the protecting element such that at least a portion of the protecting element is exposed from the light-shielding frame in the top view; disposing a first resin between the light emitting element and the substrate by applying the first resin on the substrate in a region outside of the portion of the protecting element such that the first resin moves toward the light emitting element along the protecting element; and curing the first resin to obtain a first cover member.