LED Protective Cap Sealing Electrode Gaps

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Solution Overview

Problem

Conventional LED packages face reliability issues due to gaps between insulation layers and electrodes, which can lead to moisture and air infiltration, reducing efficiency and lifespan.

Innovation Solution

A light emitting device with a protective member inserted between the electrodes, protruding into the body, to cover gaps and prevent infiltration, improving reliability by using a material different from the body with specific dimensions and structures to enhance sealing and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulation layer is inserted between the two electrodes to prevent short circuiting, then electrical insulation is improved, but gaps can form between the insulation layer and electrodes over time, reducing reliability

Engineering Contradiction:

Improveelectrical insulationVSAvoidgap formation

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent introduces a protective member as an intermediary component between the first and second electrodes. This protective member fills the gaps that form between the insulation layer and electrodes, preventing moisture and air infiltration while maintaining electrical insulation. The protective member acts as a mediator that addresses both the insulation requirement and the gap formation problem simultaneously.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the protection function into two distinct components: the insulation layer for electrical isolation and the protective member for physical gap sealing. This segmentation allows each component to specialize in its specific function - the insulation layer maintains electrical separation while the protective member prevents gap formation and environmental contamination.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the protective member protrudes into the body to cover gaps, then sealing performance is improved, but device complexity increases

Engineering Contradiction:

Improvesealing performanceVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective member is designed to perform multiple functions simultaneously: it seals gaps between the insulation layer and electrodes, prevents moisture and air infiltration, and provides mechanical support. By consolidating these functions into a single component, the patent improves sealing performance without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The protective member is implemented as a thin-walled structure that can flexibly adapt to the internal geometry of the LED package. This thin-film approach provides effective gap coverage and sealing while minimizing the addition of volume and structural complexity to the overall device.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentEP3361519B1Light emitting device

Publication Date: 2020.10.14 SUZHOU LEKIN SEMICON CO LTD

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AI summary

Disclosed is a light emitting device and a method of manufacturing the same. The light emitting device includes a body, a first electrode installed in the body and a second electrode separated from the first electrode, a light emitting chip formed on one of the first and second electrodes, and electrically connected to the first and second electrodes, and a protective cap projecting between the first and second electrodes.