LED Mounting Structure With Thin-Film Self-Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light-emitting devices face issues with positional deviation of light-emitting elements due to mismatches in arrangement regions, leading to misalignment of the optical axis.
Innovation Solution
A light-emitting device design featuring plate-shaped base materials with an insulating coating film and a thin film portion surrounding the opening, along with a placing pad and bonding member, allowing for self-alignment and stable bonding of the light-emitting element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the arrangement region area is significantly different from the light-emitting element area, then the light-emitting element cannot be self-aligned, but increasing the arrangement region area leads to positional deviation and optical axis misalignment
Solution Approach 1:
The coating film is segmented into different thickness regions: a thin film portion surrounding the opening portion and a thick film portion in other regions. This segmentation enables the light-emitting element to self-align through capillary action in the thin film region while the thick film region provides structural support and insulation, resolving the contradiction between positioning precision and device complexity
Solution Approach 2:
The coating film exhibits local quality variation with different thicknesses in different regions. The thin film portion (5-20 μm) around the opening allows self-alignment, while the thick film portion provides mechanical strength and electrical insulation. This local differentiation enables precise positioning without requiring complex overall structure design
2Reliability
If a thick coating film is used to cover the base material, then insulation and binding are improved, but self-alignment of the light-emitting element is hindered
Solution Approach 1:
The coating film is divided into functional segments: a thin film portion (5-20 μm) surrounding the opening for self-alignment and a thick film portion for insulation and binding. This segmentation allows each region to optimize its thickness for its specific function, resolving the contradiction between insulation reliability and self-alignment precision
Solution Approach 2:
Different regions of the coating film have different thickness qualities tailored to their functions. The thin film region provides capillary action for self-alignment, while the thick film region provides electrical insulation and mechanical binding, eliminating the need to choose between insulation and alignment
3Ease of manufacture
If the coating film is formed uniformly across the base material, then manufacturing is simplified, but the light-emitting element cannot achieve stable self-alignment
Solution Approach 1:
The coating film manufacturing process is segmented to create different thickness zones: a thin film portion surrounding the opening and a thick film portion elsewhere. This can be achieved through controlled deposition or etching processes, maintaining manufacturing simplicity while enabling self-alignment functionality
Solution Approach 2:
The thin film portion is formed in advance around the opening region before light-emitting element placement. This preliminary structural preparation creates the capillary action pathway that guides self-alignment during bonding, simplifying the overall manufacturing process while ensuring positioning accuracy
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 design ensures precise positioning of the light-emitting element, preventing misalignment and enhancing bonding stability, thereby improving the device's optical axis alignment.
Implementation Method 1
the coating film includes a thin film portion in which the coating film is formed in a thin film so as to surround an outer peripheral end of the opening portion
Data Source
AI summary
A light-emitting device includes a plurality of plate-shaped base materials, an insulating coating film, and at least one light-emitting element. The base materials are arranged side by side to be mutually spaced. The insulating coating film is formed to cover an upper surface and a side surface of each of the plurality of base materials. The coating film is provided with an opening portion that exposes one region of the upper surface of one base material and includes a binding portion mutually binding the plurality of base materials. The at least one light-emitting element is placed on the one region. The coating film includes a thin film portion in which the coating film is formed in a thin film to surround an outer peripheral end of the opening portion.