Light-emitting Device Reflective Member Groove Singulation

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Solution Overview

Problem

Existing light-emitting devices manufactured using conventional methods lack visibility and efficiency in the manufacturing process, particularly in singulating light-emitting elements with resin or similar materials.

Innovation Solution

A method involving arranging light-emitting elements with a first reflective member covering lateral surfaces, a light-transmissive member with phosphor, and a second reflective member to enhance visibility and manufacturing efficiency, including forming grooves and singulating the device by cutting the second reflective member.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If resin is used to fill gaps between light-emitting elements, then the device can be manufactured, but visibility is poor and precise alignment is required

Engineering Contradiction:

Improvemanufacturing processVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies color changes by using a reflective member with a reflective layer that has a white or light-colored appearance. This reflective layer is disposed between the light-emitting elements and reflects light upward, creating high visibility without requiring precise alignment during manufacturing. The color change principle transforms the invisible resin-filled gaps into visible light-reflecting structures.

Inventive Principle:

Principle #32Color changes

2Ease of manufacture

If resin is used to cover light-emitting elements, then manufacturing is simplified, but light extraction efficiency decreases and heat accumulates

Engineering Contradiction:

Improvemanufacturing processVSAvoidlight extraction efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent extracts the light-extraction function from the resin material and assigns it to a dedicated reflective member with a reflective layer. This reflective member is specifically designed to reflect light upward rather than absorb it, thereby improving light extraction efficiency while maintaining the manufacturing simplicity of using resin as a filler material.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the potentially harmful effect of resin absorption into a beneficial reflection by introducing a reflective member. The reflective layer, with its white or light-colored appearance, transforms the resin's light-absorbing property into a light-reflecting property, improving both visibility and light extraction efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If conventional manufacturing methods are used, then production can proceed, but visibility and distinguishability of the device are poor

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidvisibility

Core Design Contradiction:

ProductivityVSIllumination intensity

Solution Approach 1:

Inventive Principle:

Principle #32Color changes

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 provides a light-emitting device with improved visibility and efficient manufacturing by ensuring most light is emitted from the upper surfaces, reducing heat absorption, and simplifying the manufacturing process by eliminating precise alignment requirements.

Implementation Method 1

a light-transmissive member (40) on the covering member (30), the light-transmissive member (40) having lateral surfaces and comprising a phosphor

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Implementation Method 2

disposing a first reflective member between the plurality of light-emitting elements such that the upper surface of each of the plurality of light-emitting elements are exposed and such that lateral surfaces of the light-emitting elements are covered with the first reflective member

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS11424384B2Light-emitting device and method of manufacturing the same

Publication Date: 2022.08.23 NICHIA CORP

AI summary

A method of manufacturing a light-emitting device includes: arranging a plurality of light-emitting elements each having an upper surface; disposing a first reflective member between the plurality of light-emitting elements such that the upper surface of each of the plurality of light-emitting elements are exposed and such that lateral surfaces of the light-emitting elements are covered with the first reflective member; disposing a light-transmissive member over the upper surface of each of the plurality of light-emitting elements and the first reflective member; forming a plurality of grooves surrounding one or two or more light-emitting elements by removing a portion of the light-transmissive member and a portion of the first reflective member; disposing a second reflective member to fill the plurality of grooves; and cutting the second reflective member to perform singulation.