Light Emitting Device Recessed Substrate Soldering Strength

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Solution Overview

Problem

Existing LED modules with solder fillets on the edges of substrates are prone to cracking or chipping, especially when the modules are thinner, due to reduced mechanical strength.

Innovation Solution

A light emitting device design featuring a base body with a recess on one end face, allowing connection terminals to extend over the recess, enhancing soldering strength while maintaining mechanical strength, even in thin configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If the LED module is made flatter (thinner) to reduce size, then compactness is improved, but the mechanical strength deteriorates increasing risk of cracking or chipping

Engineering Contradiction:

Improvethickness of moduleVSAvoidmechanical strength of substrate

Core Design Contradiction:

Length of moving objectVSStrength

Solution Approach 1:

The recess segments the substrate thickness into distinct regions: the recess portion and the remaining substrate thickness. This segmentation allows the connection terminals to be distributed through the recess depth rather than requiring the entire substrate thickness to be reduced, maintaining mechanical strength while achieving a thin overall profile.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The recess acts as a nested cavity within the substrate thickness, containing the connection terminals within this nested structure. This nesting allows the terminals to extend through the recess without requiring the entire substrate to be thick, enabling thin module design while preserving mechanical strength.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If connection terminals extend over the recess to increase soldered surface area, then soldering strength is improved, but the complexity of the base body structure increases

Engineering Contradiction:

Improvesoldering strengthVSAvoidstructure of base body

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The recess is formed in the base body before the connection terminals are installed, creating a pre-prepared structure that guides the terminals into the correct position. This preliminary action simplifies the overall manufacturing process by integrating the recess formation with the base body fabrication, reducing the need for separate complex assembly steps.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9299904B2Light emitting device

Publication Date: 2016.03.29 NICHIA CORP

AI summary

A light emitting device including; a base body having a base material that includes a first main face that has a lengthwise direction and a short-side direction that is perpendicular to the lengthwise direction, a second main face on the opposite side from the first main face, a first end face that extends in the lengthwise direction, and a second end face that extends in the short-side direction, and connection terminals that are provided on the first main face of the base material; and a light emitting element that is installed on the first main face and is connected to the connection terminals, the first end face of the base material has a recess that is contiguous with the first main face and the second end face and/or is contiguous with the second main face and the second end face, a length of the recess in a lengthwise direction is greater than a depth in a short-side direction, and the connection terminals are provided extending over the recess.