LED Lighting Module Protecting Dam Prevents Short Circuits
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Solution Overview
Problem
Existing LED lighting modules for vehicle headlamps face challenges in maintaining optimal light intensity and directional control, with issues of short circuits and shadow creation during the die-bonding process, and require a compact and efficient design to comply with traffic regulations.
Innovation Solution
A LED lighting module with LED components having a perpendicular structure, a carrier with a protecting dam, and a wavelength-converting layer, where the distance between adjacent LED components is between 0.05 mm and 0.10 mm, and the wavelength-converting layer's thickness is less than half the height of the LED die, preventing short circuits and ensuring uniform light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the distance between adjacent LED components is reduced to increase light intensity, then illumination intensity is improved, but short circuit risk increases during die-bonding
Solution Approach 1:
The patent introduces a protecting dam structure as an intermediary element positioned between adjacent LED components. This dam creates a physical barrier that prevents direct contact between bonding materials of neighboring LEDs during the die-bonding process, thereby eliminating short circuit risks while allowing the LEDs to be positioned at minimal spacing for maximum light intensity.
2Volume of moving object
If LED components are placed closer together to reduce module size, then device compactness is improved, but shadow creation during die-bonding worsens
Solution Approach 1:
The protecting dam serves as a mediator that manages the bonding process between closely spaced LED components. By providing a defined boundary and support structure, it ensures uniform bonding material distribution and prevents shadow formation that would otherwise occur when components are positioned at minimal distances for compactness.
3Adaptability or versatility
If LED components are positioned at minimal spacing to comply with regulations, then regulatory compliance is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The protecting dam is pre-formed on the substrate before LED components are positioned. This preliminary structure provides predetermined positioning references and bonding boundaries, thereby reducing the actual positioning precision requirements during assembly while enabling minimal spacing configurations that meet regulatory standards.
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 solution prevents short circuits and undesirable shadows, maintains optimal light intensity, and ensures compliance with regulatory requirements by providing a compact and efficient LED package for vehicle headlamps.
Implementation Method 1
A light emitting diode (LED) is a kind of semiconductor device, which exploits the property of direct-bandgap semiconductor material to convert electric energy into light energy efficiently
Implementation Method 2
Each LED die 102 emits blue light from its top surface 1020
Data Source
AI summary
A light emitting diode (LED) lighting module includes a plurality of LED components and a carrier. The LED components are electrically connected in series, and each LED component includes a LED die having a perpendicular structure. The carrier includes a substrate and a protecting dam, the LED components and the protecting dam are respectively placed on the substrate, and a height of the protecting dam is higher than that of each LED component. When a specific condition is satisfied, a short circuit condition between two adjacent LED components when performing die-bond procedure is prevented.