Light-Emitting Module Manufacturing With Divided Transmissive Member
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Solution Overview
Problem
Existing light-emitting modules have large intervals between light-emitting surfaces, limiting their density and efficiency in applications such as adaptive driving beam headlights, where a compact and densely packed light source is desired.
Innovation Solution
A method of manufacturing a light-emitting module that involves forming a light-transmissive member joined body with submounts and light-emitting elements, dividing the light-transmissive member to create element structures with small intervals, and using a first covering member with high light reflectance to cover lateral surfaces, allowing for closer packing and improved light extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional light-emitting module structure is used, then the module can be manufactured with standard processes, but the intervals between light-emitting surfaces are large, reducing density and efficiency
Solution Approach 1:
The patent merges multiple light-emitting elements and their individual light-transmissive members into a single integrated structure. The light-transmissive member is formed to cover multiple light-emitting elements simultaneously, creating a joined body that reduces the intervals between light-emitting surfaces while simplifying the manufacturing process through unified formation rather than separate assembly of each component
Solution Approach 2:
The patent segments the light-transmissive member into multiple regions corresponding to individual light-emitting elements after the initial unified formation. This segmentation allows each region to be optimized for its specific light-emitting element while maintaining the overall compact structure, enabling dense packing without sacrificing individual element performance
2Volume of moving object
If the intervals between light-emitting surfaces are reduced, then the module becomes more compact and efficient, but the manufacturing process becomes more complex
Solution Approach 1:
The patent transitions from a two-dimensional arrangement where light-emitting elements are placed side-by-side with significant spacing to a three-dimensional integrated structure. The light-transmissive member extends vertically to cover multiple elements, utilizing the vertical dimension to reduce horizontal intervals and achieve compactness without excessive structural complexity
3Length of moving object
If a single light-transmissive member covers multiple light-emitting elements, then the intervals between light-emitting surfaces are reduced, but the light extraction efficiency may be compromised
Solution Approach 1:
The patent applies local quality by forming the light-transmissive member with different properties in different regions. Each region corresponding to a light-emitting element is optimized for that specific element's characteristics, allowing light extraction efficiency to be maintained or enhanced despite the reduced intervals. The material composition, thickness, or optical properties can vary locally to compensate for the closer spacing
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 enables the production of light-emitting modules with small intervals between light-emitting surfaces, enhancing their compactness and efficiency, particularly suitable for adaptive driving beam headlights by reducing the size of the headlight lens and minimizing light loss.
Implementation Method 1
a first covering member on the module board to cover lateral surfaces of the element structures
Data Source
AI summary
A method of manufacturing a light-emitting module that includes providing a light-transmissive member joined body that includes a plurality of submounts, a plurality of light-emitting elements each of which is disposed on a respective one of submounts, and a single light-transmissive member disposed on the light-emitting elements. The method further includes disposing the light-transmissive member joined body on a module board such that the submounts face the module board, forming a plurality of element structures by dividing the single light-transmissive member for each light-emitting element into the element structures each of which includes the submount, the light-emitting element, and the light-transmissive member positioned in this order, and forming a first covering member on the module board to cover lateral surfaces of the element structures.