LED Package Sealing Resin Curing Under Centrifugal Force
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Solution Overview
Problem
Light-emitting devices with light-emitting elements in a recess of a package experience unevenness in chromaticity due to the shape of the sealing resin, which affects the distribution and luminance of emitted light.
Innovation Solution
A light-emitting device is designed with a package having a recess and a sealing member that is cured under centrifugal force, creating a flat region on the upper surface to reduce chromaticity unevenness, and a method involving the use of a light reflective member to enhance light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sealing member is cured without applying centrifugal force, then the manufacturing process is simple, but the upper surface of the sealing member becomes uneven causing chromaticity unevenness
Solution Approach 1:
The patent applies centrifugal force to the uncured sealing member before curing to pre-form the resin and create a flat upper surface. This preliminary action ensures that when the resin cures, it maintains the flat shape, thereby achieving uniform chromaticity without requiring additional post-processing steps.
Solution Approach 2:
The patent changes the physical state of the sealing member by applying centrifugal force during the curing process. The centrifugal force causes the uncured resin to flow and settle into a flat configuration, and by maintaining this force during curing, the flat shape is locked in, improving chromaticity uniformity.
2Illumination intensity
If the upper surface of the sealing member is uneven, then no additional processing is needed, but light distribution becomes uneven affecting luminance uniformity
Solution Approach 1:
The patent applies centrifugal force to the uncured sealing member before curing to pre-form the resin and create a flat upper surface. This preliminary action ensures that when the resin cures, it maintains the flat shape, thereby achieving uniform chromaticity without requiring additional post-processing steps.
3Use of energy by moving object
If a light reflective member is added to improve light extraction, then light extraction efficiency improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent makes the sealing member itself serve the dual function of sealing and light extraction enhancement. By creating a flat upper surface through centrifugal force application, the sealing member optimizes its own light extraction efficiency without requiring additional light reflective members, thereby reducing device complexity.
Solution Approach 2:
The sealing member is designed to perform multiple functions: providing mechanical sealing and optimizing light extraction. The flat upper surface configuration achieved through centrifugal force application during curing enables the sealing member to effectively distribute light uniformly, eliminating the need for separate light management components.
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 effectively reduces chromaticity unevenness and improves light extraction efficiency by creating a flat region on the sealing member's surface, allowing for more uniform light distribution and reduced need for additional light reflective materials.
Implementation Method 1
curing the uncured sealing member while applying a centrifugal force to the package in which the uncured sealing member are disposed, such that the centrifugal force is applied in a direction perpendicular to the upper surface toward the bottom surface of the recess
Implementation Method 2
disposing an uncured sealing member in the recess of the package; and curing the uncured sealing member while applying a centrifugal force
Data Source
AI summary
A method of producing a light-emitting device includes: providing a package having an upper surface and a recess including an opening located at the upper surface; disposing a light-emitting element on a surface defining a bottom of the recess of the package; disposing an uncured sealing member in the recess of the package; and curing the uncured sealing member while applying a centrifugal force to the package in which the uncured sealing member are disposed, such that the centrifugal force is applied in a direction perpendicular to the upper surface and toward the surface defining the bottom of the recess.