Light Emitting Module with Mesh Conductor for High-Density LED Arrays

Solution Overview

Problem

In light emitting modules using LEDs with different electrode heights and structures, variations in connection strength occur due to inconsistent electrode arrangements, leading to potential contact failures and dielectric breakdowns when LEDs are densely arranged.

Innovation Solution

A light emitting module design featuring a conductor layer with a mesh pattern on transparent films, where LEDs with varying electrode heights are arranged such that the higher electrodes are closer, ensuring consistent contact with the conductor layer and reducing variations in connection strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If LEDs with different electrode heights are arranged close to each other to achieve high density, then productivity increases, but connection strength varies and reliability deteriorates

Engineering Contradiction:

ImproveLED arrangement densityVSAvoidconnection strength consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The conductor layer is designed with different patterns in different regions: a mesh pattern in regions where high electrodes are located and a line pattern in regions where low electrodes are located. This local differentiation ensures that each electrode type connects optimally to the conductor layer, maintaining consistent connection strength across all LEDs regardless of their electrode height variations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention transitions from a simple linear conductor trace to a two-dimensional mesh pattern for the conductor layer. This dimensional change allows the conductor to adapt to electrodes at different heights by providing multiple connection paths and contact points, thereby ensuring reliable electrical connection for both high and low electrodes simultaneously.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If LEDs with different structures are arranged close to each other to achieve high density, then productivity increases, but manufacturing precision deteriorates due to inconsistent connection strength

Engineering Contradiction:

ImproveLED arrangement densityVSAvoidconnection strength consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The conductor layer is designed with different patterns in different regions: a mesh pattern in regions where high electrodes are located and a line pattern in regions where low electrodes are located. This local differentiation ensures that each electrode type connects optimally to the conductor layer, maintaining consistent connection strength across all LEDs regardless of their electrode height variations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The mesh pattern conductor layer serves multiple functions simultaneously: it provides electrical connection for high electrodes through its interconnected structure, provides connection for low electrodes through its extended coverage, and ensures uniform connection strength across all LED positions. This multi-functional design eliminates the need for separate conductor designs for different electrode types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If LEDs are densely arranged to increase productivity, then the number of LEDs per module increases, but contact failures and dielectric breakdowns occur due to variation in connection strength

Engineering Contradiction:

Improvenumber of LEDs per moduleVSAvoidelectrical connection stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The conductor layer is designed with different patterns in different regions: a mesh pattern in regions where high electrodes are located and a line pattern in regions where low electrodes are located. This local differentiation ensures that each electrode type connects optimally to the conductor layer, maintaining consistent connection strength across all LEDs regardless of their electrode height variations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The mesh pattern conductor layer is designed in advance to accommodate potential electrode height variations and positioning tolerances. The interconnected mesh structure provides redundant connection paths that cushion against connection failures, preventing dielectric breakdowns by ensuring uniform electrical contact across all LEDs before any failure can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS10879438B2Light emitting module and manufacturing method of light emitting module

Publication Date: 2020.12.29 NICHIA CORP

AI summary

According to one embodiment, a light emitting module includes a first insulating film having optical transparency, a second insulating film arranged facing the first insulating film and having optical transparency, a conductor layer formed on the first insulating film, and a plurality of light emitting elements arranged between the first insulating film and the second insulating film and connected to the conductor layer in a first surface on one side. Each of the plurality of light emitting elements including a first electrode in which a height from a second surface opposite to the first surface is a first height and a second electrode in which a height from the second surface is a second height. The plurality of light emitting elements are arranged such that a distance between the first electrodes of adjacent light emitting elements is smaller than a distance between the second electrodes.