Light Emitting Device Recess Structure for Miniaturization
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Solution Overview
Problem
The existing methods for manufacturing light emitting devices face inefficiencies due to high viscosity of light-reflective resin, which slows down the spreading process and affects operation efficiency, and result in increased weight and size of the devices.
Innovation Solution
A method involving a base member with a first and second portion, where the light emitting element is mounted on the first portion, and the relative positional relationship between the portions is shifted to form a recess, allowing for bonding and miniaturization, with optional use of a light-reflective member for enhanced reflectance and bonding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If light-reflective resin is used to surround light emitting elements for miniaturization, then device size is reduced, but manufacturing efficiency decreases due to high viscosity and slow spreading
Solution Approach 1:
The recess is formed in the base member before mounting the light emitting elements, allowing the light-reflective resin to be applied in a controlled cavity rather than requiring it to spread across a large surface area. This preliminary structuring enables efficient resin application while achieving miniaturization.
Solution Approach 2:
The base member is designed with a specific recess structure that concentrates the light-reflective resin in a localized area surrounding each light emitting element. This local concentration approach reduces the total resin volume needed while maintaining the miniaturization effect and improving manufacturing efficiency.
2Volume of moving object
If light-reflective resin is applied after mounting light emitting elements, then device miniaturization is achieved, but operation efficiency decreases due to increased resin viscosity
Solution Approach 1:
The recess structure is prepared in advance in the base member before resin application. This preliminary action creates a defined space that guides the light-reflective resin into position without requiring it to spread against high viscosity resistance, thereby maintaining operation efficiency while achieving miniaturization.
3Ease of manufacture
If light emitting elements are mounted on a flat base member, then manufacturing is simple, but device weight increases without miniaturization
Solution Approach 1:
The base member is segmented to include a recess structure that creates a compact three-dimensional arrangement around the light emitting elements. This segmentation allows the device to achieve miniaturization and weight reduction while maintaining manufacturing simplicity through the integrated recess design.
Solution Approach 2:
The base member transitions from a flat two-dimensional structure to a three-dimensional structure with a recess. This dimensional change enables compact packaging of light emitting elements, achieving miniaturization and weight reduction while the recess can be formed using standard manufacturing processes that maintain ease of production.
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 approach enables efficient miniaturization and weight reduction of light emitting devices by allowing the light emitting element to be mounted closer to the lateral surfaces, improving light reflectance and extraction efficiency while maintaining strong bonding.
Implementation Method 1
a light-reflective member disposed in the recess and covering the light emitting element
Data Source
AI summary
A method of manufacturing a light emitting device includes: providing a substantially flat plate-shaped base member which in plan view includes at least one first portion having an upper surface, and a second portion surrounding the at least one first portion and having inner lateral surfaces; mounting at least one light emitting element on the at least one first portion; shifting a relative positional relationship between the at least one first portion and the second portion in an upper-lower direction to form at least one recess defined by an upper surface of the at least one first portion that serves as a bottom surface of the at least one recess and at least portions of the inner lateral surfaces of the second portion that serve as lateral surfaces of the at least one recess; and bonding the at least one first portion and the second portion with each other.