LED Lead Protrusion Sealing for Moisture-Resistant Packages
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Solution Overview
Problem
Existing light emitting devices face challenges in achieving high moisture resistance, which affects their reliability and performance in various applications.
Innovation Solution
A light emitting device design featuring a base with protrusions on its leads and a resin body that covers these protrusions, along with a protecting member deposited between the protrusions and the resin body, enhances moisture resistance by reducing moisture entry through the gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin body covers the leads and gaps in conventional light emitting devices, then the device structure is simplified and manufacturing is easier, but moisture resistance is insufficient due to moisture entry through gaps
Solution Approach 1:
The patent applies preliminary action by forming protrusions on the leads before assembling the device with the resin body. These protrusions are pre-configured to reduce gap formation, proactively preventing moisture entry pathways before the device is sealed, thereby improving moisture resistance without requiring complex post-assembly modifications
Solution Approach 2:
The patent applies local quality by modifying specific regions of the leads with protrusions at critical locations where gaps would form between the leads and resin body. This localized structural modification targets the specific areas prone to moisture entry, providing enhanced moisture resistance at critical interfaces without changing the overall device structure
2Reliability
If protrusions are added to leads and a protecting member is deposited to reduce gaps, then moisture resistance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the protection strategy into multiple components: protrusions on leads for mechanical gap reduction, resin body for sealing, and protecting member for additional barrier. This segmented approach allows each component to be optimized and manufactured separately using standard processes, making the overall solution easier to manufacture despite the enhanced protection
Solution Approach 2:
The patent introduces a protecting member as an intermediary substance deposited between the protrusions and the resin body. This intermediary layer fills remaining micro-gaps and provides an additional moisture barrier, enhancing protection while using a simple deposition process that integrates easily into existing manufacturing workflows
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 solution effectively increases the moisture resistance of light emitting devices, preventing degradation and improving their reliability and performance in humid environments.
Implementation Method 1
a protecting member disposed continuously on at least a portion of the first A surface and in at least a portion of a gap between the first protrusion and the resin body
Implementation Method 2
a resin body covering one of the first C surfaces and holding the first lead and the second lead
Data Source
AI summary
A light emitting device includes: a base including: a first lead including: a first A surface, a first B surface opposite to the first A surface, and a first C surface located between the first A surface and the first B surface and defining at least one first protrusion, a second lead separated from the first lead, and a resin body covering the first C surface and holding the first lead and the second lead; a light emitting element disposed on the first A surface; and a protecting member disposed continuously on at least a portion of the first A surface and in at least a portion of a gap between the first protrusion and the resin body. In a cross-sectional view, the first protrusion extends from a first end portion of the first A surface at a second lead side toward the second lead.