LED Resin Structure With Concave Surface for Light Extraction
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Solution Overview
Problem
There is a demand for improving light extraction efficiency in light emitting devices, as existing technologies do not effectively maximize the extraction of light from light emitting elements.
Innovation Solution
A light emitting device is manufactured with a support body, a light emitting element, a light-transmissive member, and a resin member, where the resin member has a concave lower surface and extended portions that increase the area for light extraction, and a covering member that protects the resin member, enhancing light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional flat resin member is used to cover the light emitting element, then the device structure is simple, but the light extraction efficiency is low
Solution Approach 1:
The resin member's lower surface is formed with a concave curved shape that corresponds to the shape of the light emitting element. This curvature increases the contact area between the resin member and the light emitting element, allowing more light to be extracted from the lateral surfaces of the light emitting element. The curved surface design transforms the flat interface into a conformal contact that captures and redirects light that would otherwise be trapped or absorbed.
2Ease of manufacture
If the resin member covers only the top surface of the light emitting element, then the manufacturing process is simple, but the light extraction area is limited
Solution Approach 1:
The resin member is designed to extend not only over the top surface of the light emitting element but also along its lateral surfaces. This three-dimensional configuration increases the light extraction area by providing multiple interfaces for light to exit the device. The resin member wraps around the light emitting element in a manner that utilizes vertical and lateral dimensions, transforming a two-dimensional coverage into a volumetric light extraction solution.
3Device complexity
If no covering member is used to protect the resin member, then the device structure is simpler, but the resin member is vulnerable to damage and contamination
Solution Approach 1:
A covering member in the form of a thin film or shell is introduced to protect the resin member. This covering layer acts as a protective barrier against mechanical damage, contamination, and environmental factors while maintaining the optical properties of the resin member. The thin film design provides protection without significantly increasing device complexity or interfering with light extraction functionality.
Data Source
AI summary
A method of manufacturing a light emitting device including: providing an intermediate structure including an light emitting element and a support body; securing a plate-shaped intermediate resin member and the light emitting element with a light-transmissive member such that the intermediate resin member includes first resin extended portions extending outwardly in the first direction respectively from both short sides of the light emitting element in a plan view; cutting the intermediate resin member at cutting positions along the second direction to obtain a resin member with a concave lower surface, a maximum distance from the light emitting element to a respective one of the cutting positions in the first direction being longer than a maximum length of the light emitting element in the second direction; and forming a covering member to cover lateral surfaces of the resin member such that an upper surface of the resin member is exposed.