Light-Emitting Device Deformation Prevention Layer
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Solution Overview
Problem
Light-emitting devices with amorphous fluororesin sealing face limitations in high-temperature heat treatments, as the amorphous fluororesin softens and changes shape, restricting processes like solder reflow for mounting on implementation devices, particularly in ultraviolet sterilization applications.
Innovation Solution
A deformation-prevention layer composed of a thermosetting or ultraviolet curing resin is applied to cover the amorphous fluororesin, preventing shape changes during heat treatment, allowing for higher temperature processing without impairing the device's performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solder reflow process is applied to mount the light-emitting device, then adequate wettability and secure bonding are achieved, but the amorphous fluororesin softens and changes shape due to high temperature
Solution Approach 1:
A protective coating layer is formed on the surface of the amorphous fluororesin before the solder reflow process. This preliminary action protects the fluororesin from heat-induced deformation during subsequent high-temperature soldering, allowing reliable bonding without shape change.
2Ease of manufacture
If high-temperature heat treatment is applied to ensure solder wettability, then secure mounting is achieved, but the amorphous fluororesin cannot maintain its shape
Solution Approach 1:
A protective coating layer acts as an intermediary between the heat source and the amorphous fluororesin. This intermediate layer allows heat to pass through for soldering while preventing the fluororesin from directly experiencing the full thermal stress that would cause deformation.
3Illumination intensity
If the light-emitting device uses amorphous fluororesin sealing, then optical performance is maintained, but heat treatment processes are restricted
Solution Approach 1:
The protective coating is applied in advance to enable subsequent heat treatment processes that would otherwise be impossible with amorphous fluororesin alone, expanding process adaptability while preserving optical performance.
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 enables light-emitting devices to undergo heat treatments at temperatures that would otherwise alter the amorphous fluororesin's shape, ensuring stable optical characteristics and performance, even after shipment, by using a deformation-prevention layer that covers the amorphous fluororesin and prevents shape changes.
Implementation Method 1
the deformation-prevention layer comprises a layer in which a thermosetting resin or an ultraviolet curing resin is cured
Implementation Method 2
the deformation-prevention layer comprises a layer in which a thermosetting resin or an ultraviolet curing resin is cured
Implementation Method 3
the amorphous fluororesin is softened by heat, and the shape is changed
Data Source
AI summary
A light-emitting device 1 comprises a base 30, a nitride semiconductor light-emitting element 10 flip-chip mounted on the base 30, and an amorphous fluororesin sealing the nitride semiconductor light-emitting element 10. The light-emitting device 1 comprises a deformation-prevention layer 60 for preventing a shape change of an amorphous fluororesin by heat treatment after shipment of the light-emitting device 1, and the deformation-prevention layer 60 is formed of a layer in which a thermosetting resin or an ultraviolet curing resin is cured, and the cured layer directly covers the surface of the amorphous fluororesin.