Light Emitting Apparatus Reflection Frame Assembly
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Solution Overview
Problem
Conventional light emitting apparatuses suffer from lateral light leakage and complex assembly processes due to the direct fixation of reflection frames on circuit substrates with concave-convex shapes, which also limits the flexibility in selecting the shape of the reflection frame.
Innovation Solution
A light emitting apparatus design featuring a diffusing resin layer with through-holes that engages with the protruded portions of the reflection frame, allowing for easy assembly and preventing lateral light leakage, while enabling the free selection of reflection frame shapes by using recessed and protruded steps on the reflective resin and reflection frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the reflection frame is directly fixed on the circuit substrate, then the assembly process becomes complex and time-consuming, but the fixation appears simple at first glance
Solution Approach 1:
The patent introduces a reflection frame fixing member as an intermediary component between the circuit substrate and the reflection frame. This fixing member includes a pressing portion that contacts the circuit substrate and a protruding portion that engages with the reflection frame, mediating the connection between the two components. This intermediary structure simplifies the assembly process by providing a standardized interface while reducing production time through efficient fixation.
2Reliability
If the reflection frame is directly fixed on the circuit substrate with concave-convex shape, then the fixation is straightforward, but gaps are generated causing light leakage
Solution Approach 1:
The patent applies local quality by designing the reflection frame fixing member with differentiated functional regions: a pressing portion with a specific shape that conforms to the concave-convex structure of the circuit substrate for stable contact, and a protruding portion that engages with the reflection frame. This localized optimization of structure at different positions ensures both light sealing reliability and structural simplicity.
3Adaptability or versatility
If the reflection frame shape is constrained by the circuit substrate layout, then the assembly is simplified, but the shape selection of reflection frame is limited
Solution Approach 1:
The patent segments the fixation function from the reflection frame body by introducing a separate fixing member. This segmentation allows the reflection frame to be designed with various shapes (circular, rectangular, triangular, etc.) independent of the circuit substrate layout, while the standardized fixing member handles the assembly connection. This separation enhances adaptability for different reflection frame shapes while maintaining ease of manufacture through modular assembly.
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 effectively prevents lateral light leakage and simplifies the assembly process, ensuring efficient light collection and allowing for various reflection frame configurations, thereby enhancing light emitting efficiency and assembly ease.
Implementation Method 1
the surroundings of an LED device are covered with a reflective resin such as a white resin for improving the upward light emission efficiency by reflecting upward the light emitted laterally by the LED device
Implementation Method 2
a diffusing resin layer being layered on the upper surfaces of the phosphor layer and the reflective resin
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Provided is a light emitting apparatus that causes no lateral light leakage, enables easy assembly, and allows free selection of the shape of a reflection frame. The light emitting apparatus (10, 20, 30, 40, 50, 60, 70, 80) includes an LED device (1) which is flip-chip mounted on a substrate (7), a phosphor layer (2, 42, 52, 62, 72) placed on a light emitting surface of the LED device, a reflective resin (3, 43) having a recessed portion (3a) formed on the upper surface thereof, the reflective resin covering the side surface of the LED device and the side surface of the phosphor layer, and a reflection frame (9, 49, 69, 79, 89) having a protruded portion (9a) formed on the lower surface (9d) thereof, the reflection frame being fixed on or above the phosphor layer and the reflective resin by engaging the protruded portion with the recessed portion of the reflective resin.