Light-Emitting Device Manufacturing with Light-Reflective Resin
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Solution Overview
Problem
Existing light-emitting devices face challenges in efficiently extracting light and achieving a significant difference in luminance between the inside and outside of the light exit surface, which affects their performance in applications like vehicle lighting.
Innovation Solution
A method involving a light-emitting device structure that includes a light-shielding frame with a recessed portion continuous with a through hole, a light-transmissive member with a flange, and a light-reflective resin to form an optical member, enhancing light extraction efficiency and bonding strength by preventing void generation during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a light-shielding frame with a through hole is used to extract light from the light-emitting element, then light extraction efficiency is improved, but voids may form between the light-transmissive member and the light-shielding frame, reducing bonding strength
Solution Approach 1:
The light-reflective resin is supplied onto the light-shielding frame before the light-transmissive member is positioned. This preliminary action ensures that the resin is already in place to fill any potential voids and provide bonding, preventing void formation that would otherwise occur during assembly.
Solution Approach 2:
The light-reflective resin acts as an intermediary material between the light-shielding frame and the light-transmissive member. It serves dual functions: optically reflecting light to improve extraction efficiency while simultaneously providing adhesive bonding to maintain structural strength, thus resolving the contradiction between these two requirements.
2Illumination intensity
If the light-transmissive member is positioned within the through hole to achieve large luminance difference, then light distribution is improved, but manufacturing complexity increases
Solution Approach 1:
The light-reflective resin combines multiple functions into a single material: optical reflection to enhance light extraction, adhesive bonding to join components, and void prevention to ensure structural integrity. This merging reduces manufacturing complexity by eliminating the need for separate reflective coatings and adhesive layers.
Solution Approach 2:
The refractive index of the light-reflective resin is specifically selected to create optimal optical contrast between the light exit surface and surrounding areas. By adjusting this physical parameter, the resin achieves both the desired luminance difference and effective light reflection without requiring complex multi-layer structures.
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 method allows for the simple manufacturing of light-emitting devices with enhanced light extraction efficiency and increased luminance difference between the inside and outside of the light exit surface, suitable for high-performance applications such as vehicle lighting.
Implementation Method 1
supplying a light-reflective resin on at least the flat portion of the second main surface of the light-shielding frame
Implementation Method 2
providing a light-transmissive member having a first surface having an outer perimeter that is smaller than an inner perimeter of the through hole
Implementation Method 3
forming a first light-reflective member by curing the light-reflective resin to bond the light-shielding frame and the light-transmissive member with each other via the first light-reflective member
Data Source
AI summary
A method of manufacturing a light-emitting device includes: placing a light-emitting element; providing a light-shielding frame; supplying a light-reflective resin; providing a light-transmissive member; forming an optical member; and bonding an upper surface of the light-emitting element and a surface of the light-transmissive member with each other.