Light-emitting Device with Segmented Resin Dam for Compact Sealing
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Solution Overview
Problem
Conventional light-emitting devices face challenges in reducing the size of light-emitting elements due to issues with the formation of a sufficient frame of light-reflective resin, which obstructs the reduction in width and leads to increased size, and the matrix resin exudation covering electronic components, affecting contact points and light distribution.
Innovation Solution
A light-emitting device configuration that includes a light-emitting element on a mount substrate with a reflective resin and dams on opposite sides, where the dams have a resin dam and a surface layer, with the inner lateral surface facing the light-emitting element covered and the outer lateral surface exposed, allowing for precise placement and reduced size without resin exudation, enhancing bonding strength and light emission sharpness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the light-reflective resin is applied to surround the light-emitting element, then the light distribution is improved, but the matrix resin exudation covers the electronic components and reduces contact point properties
Solution Approach 1:
The light-reflective resin is divided into multiple segments applied in sequential steps rather than a single application. This segmentation allows control over resin flow and prevents excessive matrix resin exudation from covering electronic components, while still achieving adequate light distribution through the segmented reflective structure
Solution Approach 2:
Electronic components are positioned and secured before the light-reflective resin application. This preliminary action ensures that components are protected and properly positioned before the resin is applied, preventing matrix resin exudation from compromising contact point properties
2Reliability
If the frame of light-reflective resin is made taller to seal the light-emitting element, then sealing is improved, but the device size increases
Solution Approach 1:
The light-reflective resin frame is designed with varying heights at different locations. The frame is taller at critical sealing positions and shorter at non-critical positions, achieving adequate sealing reliability while minimizing overall device size through localized height optimization
3Length of stationary object
If the frame of light-reflective resin is made narrower to reduce device size, then compactness is improved, but matrix resin exudation obstructs the narrowing
Solution Approach 1:
The viscosity parameters of the light-reflective resin are optimized to control flow behavior during application. By adjusting resin viscosity and application parameters, the resin can be precisely placed in narrow frames without excessive exudation, enabling compact device design with controlled frame width
Data Source
AI summary
A light-emitting device includes a light-emitting element disposed on a mount substrate, a reflective member disposed around the light-emitting element to cover the light-emitting element, and a dam disposed on opposite sides of the reflective member. The dam includes a resin dam, and a surface layer covering at least part of a surface of the resin dam. The inner lateral surface of the resin dam facing the light-emitting element is covered with the surface layer, and at least part of the outer lateral surface of the resin dam not facing the light-emitting element is an exposed surface.