Light Emitting Device with Segmented Reflector for Compact Packaging
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Solution Overview
Problem
Conventional surface mount type light emitting devices have limitations in size reduction due to package constraints, and exposed lateral faces of light emitting elements result in poor visibility and light leakage, blurring the distinction between emitting and non-emitting portions.
Innovation Solution
A light emitting device design featuring a light transmissive member covering the upper face of the light emitting element, surrounded by a first reflector, and lateral faces covered by a second reflector, with a manufacturing method involving a baseplate, resin frames, and resin coating steps to create a compact, clearly defined light emitting portion without a separate package.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a package is used to house the light emitting element, then the light emitting element is protected, but the device size cannot be reduced further
Solution Approach 1:
The invention extracts and eliminates the separate package structure from the conventional design. The light emitting element is mounted directly on the circuit board without an enclosing package, achieving miniaturization while maintaining functionality through alternative protective measures
Solution Approach 2:
The reflector is divided into multiple segments (first reflector portion, second reflector portion, third reflector portion) that can be separately formed and positioned. This segmentation allows for precise control of light reflection paths while enabling compact integration directly on the circuit board without requiring a bulky single-package structure
2Device complexity
If the lateral faces of the light emitting element are exposed, then the device structure is simplified, but light leakage occurs and visibility is poor
Solution Approach 1:
The reflector provides localized light management functions at different positions: the first reflector portion covers the lateral face to prevent light leakage, the second reflector portion directs light toward the circuit board, and the third reflector portion covers the lower face. This localized functional differentiation effectively controls light paths without requiring complex overall structure
Solution Approach 2:
The reflector acts as an intermediary element between the light emitting element and the surrounding environment. It mediates the light paths by reflecting and directing light in specific directions, preventing harmful light leakage while maintaining a simplified device structure without needing a enclosing package
3Ease of manufacture
If the first reflector bottom face is coplanar with the light transmissive member lower face, then manufacturing is simplified, but light leakage occurs at the interface
Solution Approach 1:
The first reflector bottom face is positioned at a different height level (non-coplanar) relative to the light transmissive member lower face, creating a vertical dimension offset. This dimensional change effectively seals the interface region, preventing light leakage from escaping laterally at the junction between these two 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 enhances light extraction efficiency, reduces light leakage, and provides clear visibility by defining the light emitting portion effectively, while allowing for compact design and cost-effective manufacturing.
Implementation Method 1
a light transmissive member covering at least a portion of the upper face of the light emitting element and transmitting the light emitted from the light emitting element
Implementation Method 2
a first reflector retaining the light transmissive member; and a second reflector covering the lateral faces of the light emitting element
Data Source
AI summary
A method for manufacturing a light emitting device includes: preparing a baseplate having a plate surface on which a protrusion is disposed; forming a first resin frame having an opening on the plate surface, wherein the opening is located above the protrusion; forming a second resin in the opening; detaching the baseplate; bonding a light emitting element to a surface of the second resin surface that has been exposed as a result of detaching the baseplate; and forming a third resin that surrounds lateral faces of the light emitting element and that covers and contacts a portion of the first resin frame.