Light Emitting Device Masking for Abrasive Blasting
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Solution Overview
Problem
Existing methods for manufacturing light emitting devices using abrasive blasting to reduce reflection of extraneous light result in reduced joining strength between the lead electrode and the mounting board due to the abrasive blasting of the lead frame surfaces.
Innovation Solution
A method involving a mask with through holes is used to expose only the surfaces of the resin molded body and light-transmissive member to abrasive blasting, preventing the lead frame surfaces from being roughened, thus maintaining the joining strength while reducing extraneous light reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If abrasive blasting is performed on the lead frame surface to reduce extraneous light reflection, then the optical performance is improved, but the joining strength between the lead electrode and mounting board is reduced
Solution Approach 1:
The patent applies local quality by differentiating the surface treatment requirements for different regions. The resin molded body and light-transmissive member surfaces are roughened via abrasive blasting to reduce light reflection, while the lead frame surface is kept smooth to maintain joining strength. This is achieved by selectively exposing only the resin molded body and light-transmissive member to the abrasive blasting process, preserving the lead frame's original surface properties for strong bonding.
2Object-affected harmful factors
If the surface of the resin molded body and light-transmissive member is roughened to reduce light reflection, then the optical performance is improved, but the manufacturing complexity increases due to the need for masking
Solution Approach 1:
The patent applies segmentation by dividing the lead frame into distinct functional regions that require different surface treatments. A mask is introduced to segment the abrasive blasting process, allowing selective roughening of only the resin molded body and light-transmissive member surfaces while protecting the lead frame. This segmentation enables precise control over which surfaces receive the abrasive treatment, achieving the desired optical performance without unnecessary complexity.
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
The method effectively reduces the influence of extraneous light reflection on the light emitting device without compromising the joining strength between the lead electrode and the mounting board, ensuring strong bonding and improved optical performance.
Implementation Method 1
performing abrasive blasting by blowing a particulate material on a surface of the resin molded body and a surface of the light-transmissive member
Data Source
AI summary
A method of manufacturing a light emitting device is provided. The method includes providing a lead frame including a plurality of light emitting devices each including: a light emitting element; a resin molded body including a lead electrode on which the light emitting element is mounted, and a light-shielding member which supports the lead electrode and has a recess accommodating the light emitting element; and a light-transmissive member disposed in the recess. The method further includes: providing a mask including a plurality of through holes, and overlaying the mask on the lead frame so that the resin molded body and the light-transmissive member are exposed at the through holes; and perforating abrasive blasting by blowing a particulate material on a surface of the resin molded body and a surface of the light-transmissive member.