LED Substrate Connection Port for Automated Assembly
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Solution Overview
Problem
The assembly of lamp filaments using light emitting diodes (LEDs) is labor-intensive and inefficient, leading to low yield and long process times, making mass production challenging due to the manual placement of electrodes at opposite ends.
Innovation Solution
A light emitting device with a substrate and two groups of LED structures, connected via a port with exposed pads, allowing for automatic assembly through a connection port that facilitates machine assembly, enabling omni-directional light emission and flexible adjustment of color temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrodes are disposed at two opposite ends of the lamp filament, then the lamp filament can be electrically connected to external power, but the lamp filament becomes hard to assemble and requires manual assembly
Solution Approach 1:
The patent divides the connection structure into segments: connection pads on the substrate, connection ports with exposed pads, and separate connection devices. This segmentation allows automated pick-and-place machines to assemble components in sequence without manual intervention, while maintaining reliable electrical connections through the distributed pad and port structure
Solution Approach 2:
The connection pads are pre-formed on the substrate before LED mounting, and the connection ports are designed with exposed pads that protrude from the substrate surface. This preliminary preparation enables automated assembly equipment to directly engage and connect components without requiring complex manual alignment procedures
2Ease of manufacture
If manual assembly is used for lamp filament assembly, then assembly can be performed with simple equipment, but the yield is low and process time is long
Solution Approach 1:
The substrate serves multiple functions: it provides mechanical support for LED mounting, contains pre-formed connection pads for electrical connection, and incorporates connection ports with exposed pads for automated engagement. This multi-functionality enables a single automated assembly process to handle both mounting and electrical connection, dramatically improving productivity while keeping equipment simple
Solution Approach 2:
The connection ports with exposed pads act as intermediaries between the substrate and connection devices. These exposed pads protrude from the substrate surface and provide dedicated engagement points for automated assembly equipment, enabling high-speed machine assembly without complex manipulation while maintaining manufacturing simplicity
3Extent of automation
If connection pads are disposed on the substrate between LED groups, then automated assembly is enabled, but the structure becomes more complex with top and side openings
Solution Approach 1:
The connection ports are designed with exposed pads that are extracted or protrude from the substrate surface, creating top and side openings. This extraction allows automated assembly equipment to engage the connection pads from multiple directions without requiring complex through-substrate vias or buried connection structures, enabling automation while managing complexity through simplified port geometry
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
Enables efficient and high-yield mass production of light emitting devices and modules by simplifying the assembly process, allowing for automatic assembly and flexible lighting effects through adjustable connection pads and wavelength conversion layers.
Implementation Method 1
Light emitting diodes (LEDs) are semiconductor devices. LEDs emit light by converting electric energy into light energy. In details, LEDs apply currents to compound semiconductors so as to release excess energy in the form of light through the binding of electrons and holes.
Implementation Method 2
At least a part of light emitted from the first group and the second group of LED structures passes through the substrate and emerges from the second surface, and the light emitting device emits light in omni-directions.
Data Source
AI summary
A light emitting device includes a substrate, a first group of light emitting diode (LED) structures, a second group of LED structures, and a connection port is provided. The substrate has a first surface and a second surface opposite to the first surface. The first group of LED structures is disposed on one side of the first surface. The second group of LED structures is disposed on another side of the first surface opposite to the first group of LED structures. The connection portion includes at least an opening, and a first connection pad and a second connection pad electrically coupled to at least a part of the LED structures. The connection port is adapted to be coupled to other device through the opening. A light emitting module and an illuminating apparatus are also provided.