LED Module Seating Guide Structure for Precise Alignment
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Solution Overview
Problem
Existing light emitting modules face challenges in performance, reliability, alignment, miniaturization, light extraction efficiency, straightness of emitted light, thermal deformation due to heat generation, and prevention of particle spread during operation.
Innovation Solution
A light emitting module design featuring a substrate with seating guide layers and bonding layers to secure light emitting units, including multiple stacks with electrode connections and protective layers, enhances alignment and prevents movement, while optimizing light extraction and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light emitting units are mounted on substrate without seating guide layer, then manufacturing process is simpler, but alignment precision and positioning accuracy deteriorate
Solution Approach 1:
The seating guide layer is formed on the substrate before mounting the light emitting units. This preliminary structure provides pre-defined seating regions with precise geometric constraints (open holes with specific width dimensions) that guide the positioning of light emitting units, ensuring accurate alignment without requiring complex post-assembly adjustments
Solution Approach 2:
The seating guide layer acts as an intermediary element between the substrate and the light emitting units. It mediates the positioning relationship by providing seating regions (open holes) that physically constrain and align the light emitting units during mounting, thereby achieving precise alignment while maintaining relatively simple manufacturing processes
2Strength
If light emitting units are secured with thick bonding layer, then bonding strength is improved, but light extraction efficiency and light straightness deteriorate
Solution Approach 1:
The thickness of the bonding layer is precisely controlled within a specific range (less than the thickness of the seating guide layer, and specifically less than 100 nm in some embodiments). This parameter optimization ensures sufficient bonding strength while minimizing the bonding layer's negative impact on light extraction efficiency and light straightness, achieving a balance between mechanical strength and optical performance
3Ease of manufacture
If light emitting unit structure is enlarged, then manufacturing and handling is easier, but miniaturization and integration density worsen
Solution Approach 1:
The patent transitions from planar mounting to vertical stacking by forming multiple seating regions on different levels (first seating region, second seating region, etc.). This dimensional change allows compact integration of multiple light emitting units in the vertical direction, achieving miniaturization and high integration density while maintaining ease of manufacture through standardized sequential stacking processes
4Productivity
If multiple light emitting stacks are vertically stacked, then integration density is improved, but thermal management and heat dissipation become more difficult
Solution Approach 1:
The vertical stack is segmented into discrete light emitting units separated by seating guide layers and bonding layers. This segmentation creates thermal isolation between individual stacks while maintaining compact vertical integration, allowing heat from each stack to be managed independently and improving overall thermal dissipation efficiency in high-density configurations
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 design improves performance and reliability, facilitates miniaturization, enhances light extraction efficiency, maintains light straightness, prevents thermal deformation, and reduces particle spread, achieving a wider light emitting region.
Implementation Method 1
A light emitting diode (LED) is a light emitting device that emits light when electric current is applied thereto
Implementation Method 2
a bonding layer covering the seating guide layer and the seating region to secure the light emitting unit to the substrate
Data Source
AI summary
Disclosed is a light emitting module including a substrate and at least one light emitting unit disposed on a surface of the substrate. The light emitting module comprises a seating guide layer disposed on a surface of the substrate and having an open hole forming a seating region in which the light emitting unit is seated, wherein a width of the open hole in a first direction is greater than a length of a side of the light emitting unit in the first direction.