LED Module Resin Layout for Higher Light Extraction
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Solution Overview
Problem
Existing light emitting modules face challenges in efficiently extracting light from a large number of individually controlled light emitting elements.
Innovation Solution
A method involving a wiring board with mounted light emitting elements, where a first resin containing a light reflecting substance is disposed between the elements and their lateral faces, and a second resin with a phosphor covers the elements, enhancing light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a large number of light emitting elements are mounted on a single wiring board for individual control, then the functionality and control precision are improved, but the light extraction efficiency from each element deteriorates
Solution Approach 1:
The patent divides the lateral faces of light emitting elements into multiple regions and applies different resins to different regions. Specifically, a first resin is applied to a first region of the lateral face, a second resin to a second region, and a third resin to a third region. This segmentation allows each region to be optimized for different functions: light reflection, light extraction enhancement, and light extraction further enhancement, thereby resolving the contradiction between maintaining individual control capability and improving light extraction efficiency.
Solution Approach 2:
Different resins with specific properties are applied to different local regions of the light emitting elements' lateral faces. The first resin contains light-reflecting particles for reflection, the second resin contains phosphors for wavelength conversion, and the third resin has high light extraction properties. This local quality differentiation ensures that each area of the lateral face contributes optimally to light extraction, solving the efficiency problem while preserving the individual control architecture.
2Loss of energy
If resin is applied to cover lateral faces of light emitting elements, then light extraction efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies resins to the lateral faces of light emitting elements during the mounting process on the wiring board, before the final module assembly is completed. This preliminary application of resins (first resin to first region, second resin to second region, third resin to third region) integrates the light extraction enhancement step into the existing manufacturing flow, avoiding the need for separate post-processing steps and reducing overall manufacturing complexity despite the multiple resin applications.
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 achieves high light extraction efficiency by reflecting light upwards and ensuring optimal contact between the resins and elements, reducing voids and facilitating size reduction.
Implementation Method 1
disposing a first resin in an area of the upper face of the wiring board and outward from a region in which the light emitting elements are mounted, wherein the first resin contains a light reflecting substance
Implementation Method 2
a second resin covering the upper face of at least one of the light emitting elements and the upper face of the first resin, wherein the second resin contains a phosphor
Data Source
AI summary
A light emitting module includes: a wiring board; a plurality of light emitting elements mounted on the wiring board, each of first and second adjacent ones of the light emitting elements having an upper face, a lower face located opposite to the upper face and facing an upper face of the wiring board, and an oblique lateral face between the upper face and the lower face spreading outwards from the lower face to the upper face; a first resin disposed between the upper face of the wiring board and the lower faces of the first and second light emitting elements, and between lateral faces of the first and second light emitting elements, the first resin containing a light reflecting substance; and a second resin containing a phosphor and covering the upper face of at least one of the light emitting elements and an upper face of the first resin.