Light Emitting Element Package With Stacked Circuit Board Units
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Solution Overview
Problem
Light emitting element packages with multiple rows experience dark region formation due to insufficient space for wire-bonding, making it difficult to implement a surface light source in vehicular headlights without these dark regions.
Innovation Solution
A light emitting element package design featuring circuit board units with regions of varying heights, where light emitting elements are disposed within 100 µm of each other horizontally, and a phosphor layer is used to optimize light output and prevent dark region formation by ensuring adequate space for wire-bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light emitting elements are arranged in three or more rows with adequate separation distances to prevent dark regions, then illumination uniformity is improved, but spaces required for wire-bonding of internal light emitting elements cannot be assured
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional stacked configuration with multiple levels. Light emitting elements are arranged on different vertical levels (first level, second level, third level) rather than only in horizontal rows. This vertical stacking allows elements to be positioned closer horizontally while maintaining adequate wire-bonding spaces on each level, thus preventing dark regions while ensuring manufacturability.
Solution Approach 2:
The patent divides the light emitting element array into multiple independent levels or stacks. Each level contains light emitting elements that are wire-bonded separately to circuit boards at that level. This segmentation allows independent optimization of wire-bonding spaces at each level while achieving overall high illumination uniformity through the combined effect of multiple closely-spaced levels.
2Illumination intensity
If light emitting elements are arranged closely to achieve surface light source effect, then dark regions are eliminated, but spaces for wire-bonding of light emitting elements are insufficient
Solution Approach 1:
The invention utilizes the vertical dimension to resolve the horizontal spacing conflict. By stacking light emitting elements on multiple vertical levels, each level can maintain adequate wire-bonding spaces while the overall structure achieves close effective spacing for surface light source effect. The vertical separation provides the necessary room for wire-bonding operations without compromising horizontal proximity.
Solution Approach 2:
The patent implements a nested stacked structure where multiple levels of light emitting elements are arranged one above another. Each level is essentially nested within the vertical envelope of the overall structure, allowing compact horizontal arrangement while maintaining vertical clearance for wire-bonding. This nesting approach maximizes space utilization while ensuring manufacturability.
3Productivity
If multiple rows of light emitting elements are disposed adjacent to each other, then surface light source is achieved, but dark regions form due to insufficient spacing
Solution Approach 1:
The patent achieves high light output density by stacking light emitting elements vertically on multiple levels rather than only arranging them in horizontal rows. This vertical arrangement allows elements to be positioned closely in the horizontal plane (achieving surface light source effect) while maintaining adequate wire-bonding spaces on each level, thus preventing dark regions while maximizing productivity.
Solution Approach 2:
The invention combines multiple levels of light emitting elements into a single integrated stacked structure. The light output from all levels is merged to achieve high overall luminosity and surface light source effect. This merging of multiple levels allows the system to achieve high productivity without requiring large horizontal separation distances that would create dark regions.
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 design enables the creation of a surface light source in vehicular headlights without dark regions, allowing for local dimming and efficient light distribution by ensuring proper spacing and output symmetry across different regions.
Implementation Method 1
A light emitting element package includes circuit board units having different heights, light emitting elements disposed in the circuit board units, and a phosphor layer disposed on the light emitting elements
Data Source
Figure 1~2
Figure 3~4a
Figure 4b~5a
AI summary
A light-emitting element package, according to one embodiment of the present invention, comprises: a circuit board including first and second regions having different heights; light-emitting elements respectively disposed in the first and second regions; and phosphor layers respectively disposed on the light-emitting elements, wherein the light-emitting elements are disposed within a 100-µm distance in the horizontal direction.