Side View LED Package Molding with Segmented Flat and Tapered Surfaces
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Solution Overview
Problem
Existing manufacturing methods for side view type light emitting devices face issues with package body detachment during suction and improper alignment during surface mounting, leading to reduced yield and productivity due to alignment errors and inadequate release properties in injection molding.
Innovation Solution
The method involves using an injection molding mold with convex and concave parts forming flat surfaces on the package body, ensuring alignment and stability during molding, and providing tapered surfaces to prevent detachment and ensure correct alignment during surface mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tapered surfaces are formed on the inclined block part to improve release properties during injection molding, then productivity is improved, but the package body becomes unstable during suction and conveyance
Solution Approach 1:
The package body is divided into two functional zones: the inclined block part with tapered surfaces for mold release, and the box-shaped block part with parallel surfaces for stable suction and conveyance. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
Different surface geometries are applied to different parts of the package body: tapered surfaces on the inclined block part for easy mold release, and parallel surfaces on the box-shaped block part for stable suction handling. Each local area has optimized quality for its specific purpose.
2Manufacturing precision
If a stepped portion is formed at the boundary between box-shaped block part and inclined block part to absorb alignment errors, then manufacturing precision is improved, but the package body becomes prone to detachment during suction
Solution Approach 1:
The package body is segmented into two distinct block parts with different geometries, where the box-shaped block part provides a stable suction surface while the inclined block part accommodates alignment tolerances through its tapered surfaces.
Solution Approach 2:
The box-shaped block part acts as an intermediary element that provides a reliable suction interface, mediating between the handling system and the inclined block part that has alignment-compensating tapered surfaces.
3Ease of manufacture
If the upper surface of the inclined block part is made into a tapered surface, then ease of manufacture is improved, but the package body cannot be correctly aligned during surface mounting
Solution Approach 1:
The package body is divided into an inclined block part with tapered surfaces for easy molding and a box-shaped block part with parallel surfaces for precise alignment during mounting, allowing each function to be optimized independently.
Data Source
AI summary
A manufacturing method of a side view type light emitting device including a package body made of a synthetic resin material, the manufacturing method includes: providing an injection molding mold, for injection-molding the package body, including: a first mold provided with a first convex part for forming an upper surface side flat part on an upper surface of the package body; and a second mold provided with a first concave part for forming the upper surface side flat part; and fitting the first concave part around the first convex part so as to enter a liquid tight state with no space, injecting the synthetic resin material into each of the first and second molds so as to be filled therein, and hardening the synthetic resin material to form the package body in a state in which the first mold and the second mold are aligned with each other.