Light-emitting Device Resin Frame Adhesion and Light Extraction
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Solution Overview
Problem
Current light-emitting devices face challenges in achieving better light extraction and adhesion of reflection members to the frame body and lead, which are essential for enhanced performance and reliability in various applications.
Innovation Solution
A light-emitting device design featuring a base body with leads supported by a resin member, a resin frame surrounding the light-emitting element, and a first resin that includes a reflective material layer and a resin layer without reflective material, where the resin layer's surface has a flat and sloped region to improve adhesion and light extraction, manufactured through a process involving centrifugal separation of the resin into distinct layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a reflection member is added to cover side surfaces, then light extraction is improved, but adhesion between the reflection member and frame body/lead deteriorates
Solution Approach 1:
The first resin is formulated as a composite material containing both reflective material (such as metal powder or white pigment) and resin matrix. This composite structure allows the resin to simultaneously provide light reflection properties and adhesion to the frame body and lead, resolving the contradiction between improving light extraction and maintaining reliable adhesion.
Solution Approach 2:
The reflective material is distributed within the resin matrix to create local reflective zones throughout the first resin. This local quality approach allows different regions of the first resin to serve different functions: adhering to substrates while also reflecting light, thereby simultaneously achieving both adhesion and light extraction improvement.
2Ease of manufacture
If a uniform resin layer is used, then manufacturing is simplified, but light extraction performance deteriorates
Solution Approach 1:
The first resin is configured with a curved upper surface that gradually increases in height from the center toward the periphery, forming a dome-like or lens-like structure. This curvature design optimizes light extraction by directing light rays at various angles, improving illumination intensity while the resin can still be applied in a single continuous layer, maintaining manufacturing simplicity.
Solution Approach 2:
The resin structure transitions from a two-dimensional flat layer to a three-dimensional curved surface, adding vertical dimensionality. This dimensional change enhances light extraction performance by creating multiple light paths and reducing total internal reflection, while the overall manufacturing process remains relatively simple through conformal coating or injection molding techniques.
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 enhances light extraction and adhesion between components, leading to improved performance and reliability of light-emitting devices by optimizing the interaction between the reflective material and the resin layers, thereby increasing the device's efficiency and durability.
Implementation Method 1
separating the first resin into a reflective material layer containing the reflective material and a resin layer not containing the reflective material, by use of revolution of the base body to apply a centrifugal force to the base body
Data Source
AI summary
A light-emitting device includes: a base member; a base body formed on an upper surface of the base member, the base body including a wiring layer; a light-emitting element mounted on an upper surface of the base body, wherein the light-emitting element includes an element-substrate, and a semiconductor layer located on the element-substrate; a resin frame located on the upper surface of the base body; and a first resin located inside the resin frame to cover a part of side surfaces of the light-emitting element, a part of inner side surface of the resin frame, and the upper surface of the base body. The first resin includes: a reflective material layer that contains a reflective material, and a resin layer that is located on an upper surface of the reflective material layer and does not contain the reflective material.