Light Emitting Device Manufacturing via Substrate Protrusion Alignment
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Solution Overview
Problem
The manufacturing of light emitting devices faces yield reduction due to positional misalignment of light emitting elements on a light transmissive substrate, leading to variance in the relative positional relationship of the light transmissive piece and the mounting unit, affecting the shape and optical characteristics of the device.
Innovation Solution
A method involving the joining of light emitting elements with a light transmissive substrate, followed by separation into pieces, mounting on a unit, and removing a portion of the substrate to achieve a predetermined shape, ensuring consistent positional relationships and reducing manufacturing variance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light emitting elements are joined to a light transmissive substrate by pressing at the junction, then the joining process is simplified, but positional misalignment occurs causing variance in the relative positional relationship of the light transmissive piece and mounting unit
Solution Approach 1:
The patent applies preliminary action by forming protrusions on the light transmissive substrate before joining the light emitting elements. These protrusions are pre-positioned at specific locations that will become the final mounting positions, ensuring that when elements are pressed onto the substrate, they automatically align with the predetermined positions rather than requiring complex alignment procedures during the joining process.
Solution Approach 2:
The protrusions on the light transmissive substrate serve as an intermediary mechanism between the joining process and the final positional alignment. These protrusions physically guide and constrain the light emitting elements to specific locations during pressing, acting as a mediator that transforms a simple pressing operation into a precision positioning process without requiring complex alignment procedures.
2Productivity
If the light transmissive substrate is cut after joining misaligned elements, then individual light transmissive pieces are obtained, but variance occurs in the shape and relative positional relationship on each mounting unit
Solution Approach 1:
The patent applies preliminary action by pre-forming protrusions at the exact final positions where light emitting elements should be located before any cutting operations. This ensures that even after the substrate is cut into individual pieces, each piece retains the protrusions at their correct positions, maintaining consistent relative positional relationships across all mounting units without requiring post-cutting adjustments.
3Productivity
If light emitting elements are joined without predetermined positioning, then the joining process is faster, but yield decreases due to misalignment variance
Solution Approach 1:
The patent applies preliminary action by creating protrusions at predetermined positions on the light transmissive substrate before the joining process. This allows light emitting elements to be quickly pressed onto the substrate without complex alignment procedures, maintaining high joining speed while ensuring that elements are automatically positioned at the correct locations, thereby preventing misalignment-related defects and maintaining high manufacturing yield.
Solution Approach 2:
The protrusions act as an intermediary positioning mechanism that enables fast joining without sacrificing yield. During the quick pressing operation, the protrusions physically guide the light emitting elements to their correct positions, serving as a mediator that reconciles the conflict between speed and precision, ensuring high yield is maintained even with simplified fast joining processes.
Data Source
AI summary
A method for manufacturing a light emitting device includes: joining a light transmissive substrate and two or more light emitting elements; separating the light transmissive substrate into a plurality of light transmissive pieces such that one or more of the light emitting elements remains in a state joined to one of the light transmissive pieces; mounting the one or more of the light emitting elements joined to the one of the light transmissive pieces on a mounting unit; removing a portion of the one of the light transmissive pieces such that a top surface of the one of the light transmissive pieces becomes a predetermined shape; and after the removing of the portion of the one of the light transmissive pieces, separating the mounting unit into a plurality of board pieces such that one or more of the light transmissive pieces remain on one of the board pieces.