LED Package Layout for Low Light Leakage and Stable Singulation
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Solution Overview
Problem
Existing light emitting devices using LEDs face challenges in achieving high front luminance and efficient manufacturing processes, particularly in reducing light leakage between adjacent light emitting elements and ensuring stable singulation of components during the manufacturing process.
Innovation Solution
The design incorporates a light emitting device with a substrate, light emitting elements, a light transmissive member, a covering member, first and second protruding members, and a protective element, where the light transmissive member is positioned between the protruding members to minimize light leakage, and the protruding members are used to control the placement and curing of the cover member, ensuring stable singulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a light emitting device uses a simple structure without protruding members, then the device complexity is reduced, but light leakage between adjacent light emitting elements increases and manufacturing precision deteriorates
Solution Approach 1:
The collective substrate is divided into multiple individual substrates through singulation, with protruding members serving as segmentation guides. The protruding members create physical boundaries that define where cutting should occur, enabling precise separation of multiple light emitting devices while maintaining manufacturing efficiency.
Solution Approach 2:
Protruding members act as intermediary structures between the collective substrate and the singulation process. These members provide reference features that guide the cutting tool during manufacturing, ensuring accurate separation without requiring complex positioning systems.
2Productivity
If light emitting elements are arranged closely to increase productivity, then the output per unit area increases, but light leakage between adjacent elements worsens
Solution Approach 1:
The harmful light leakage is extracted and redirected by the protruding members. These structures capture stray light that would otherwise leak between closely spaced elements and guide it toward the intended optical path, allowing dense packing without sacrificing optical performance.
3Ease of manufacture
If the cover member is applied without protruding members for positioning, then the ease of manufacture improves, but the manufacturing precision of component placement deteriorates
Solution Approach 1:
Protruding members are formed on the substrate before the cover member is applied. These pre-formed structures serve as positioning references that guide the cover member into correct alignment during assembly, eliminating the need for complex positioning mechanisms while ensuring precise component placement.
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
This configuration enhances light extraction efficiency, reduces light leakage between adjacent light emitting elements, and facilitates a more stable and efficient manufacturing process for the light emitting devices.
Implementation Method 1
a phosphor layer arranged above the light emitting elements and made of a light transmissive member containing phosphors for converting wavelength of light from the light emitting elements
Data Source
AI summary
A light emitting device including a substrate having a substantially rectangular shape when viewed in plan view, light emitting elements arranged along a first long side of the substantially rectangular shape of the substrate, light transmissive members each disposed on an upper surface of each of the light emitting elements, and a cover member having a substantially rectangular shape when viewed in plan view. The cover member covering an upper surface of the substrate, and exposing upper surfaces of the light transmissive members. The device includes terminals exposed from the cover member. The terminals being arranged along a second long side of the substantially rectangular shape of the substrate, and being capable of individually driving the light emitting elements. When viewed in the plan view, a long side of the substantially rectangular shape of the cover member overlaps with at least one of the first and the second long sides.