Light-Emitting Device Manufacturing Using Segmented Transmissive Substrates
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Solution Overview
Problem
The manufacturing of small or slim light-emitting devices becomes increasingly difficult as they are reduced in size, due to challenges in precision alignment and uniformity of light-emitting elements and reflectors.
Innovation Solution
A method involving a light-transmissive member with projecting portions and a light-reflective member that covers lateral surfaces of the light-emitting elements and the projecting portions, allowing for precise positioning and alignment of light-emitting elements, enhancing the precision of the emitting surface and facilitating the production of slim devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the light source device is reduced in size or slimmed down, then the device size is reduced, but the manufacturing difficulty increases
Solution Approach 1:
The light-transmissive member is divided into a base portion and multiple projecting portions, each projecting portion serving as an independent mounting platform for light-emitting elements. This segmentation enables precise positioning of multiple light-emitting elements in a compact arrangement, resolving the manufacturing difficulty that arises when reducing device size.
Solution Approach 2:
The invention transitions from a conventional planar arrangement to a three-dimensional structure by adding projecting portions that extend vertically from the base portion. This dimensional change allows light-emitting elements to be positioned at elevated locations, achieving compact horizontal spacing while maintaining proper spacing and alignment for manufacturing.
2Volume of moving object
If the light source device is reduced in size, then the device size is reduced, but the alignment precision of light-emitting elements becomes more difficult to achieve
Solution Approach 1:
By dividing the light-transmissive member into a base portion and multiple projecting portions, each projecting portion acts as an independent positioning feature. This segmentation provides distinct mounting locations for light-emitting elements, ensuring precise alignment even in compact device configurations.
Solution Approach 2:
The projecting portions serve as intermediary structures between the base portion and the light-emitting elements. These intermediaries provide elevated mounting surfaces that facilitate precise alignment and positioning of light-emitting elements, overcoming the alignment precision challenges that arise when reducing device size.
3Volume of moving object
If the light source device is reduced in size, then the device size is reduced, but the uniformity of light emission becomes more difficult to maintain
Solution Approach 1:
The segmentation of the light-transmissive member into a base portion and multiple projecting portions enables uniform distribution of light-emitting elements. Each projecting portion provides an identical mounting platform, ensuring consistent spacing and orientation of light-emitting elements, which maintains uniform light emission in compact device configurations.
Solution Approach 2:
The projecting portions provide localized elevated mounting surfaces specifically positioned to optimize light emission uniformity. By concentrating the light-emitting elements on these specially designed local structures, the invention ensures uniform light distribution while maintaining reduced overall device size.
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
This method enables the easy manufacturing of small or slim light-emitting devices by improving the precision of the emitting surface and alignment, while maintaining the necessary thickness for efficient light extraction and luminance.
Implementation Method 1
forming a light-reflective member that covers at least one of (i) lateral surfaces of the light-emitting element, and/or (ii) lateral surfaces of the projecting portion of the light-transmissive member
Data Source
AI summary
A method for manufacturing a light-emitting device includes: providing a light-transmissive member comprising: a base portion, and a projecting portion on a first surface side of the base portion; providing a light-emitting element that has a main emitting surface and an electrode formation surface opposite to the main emitting surface; disposing the light-emitting element on the projecting portion of the light-transmissive member such that the main emitting surface of the light-emitting element faces an upper surface of the projecting portion of the light-transmissive member; and forming a light-reflective member that covers at least one of (i) lateral surfaces of the light-emitting element, and/or (ii) lateral surfaces of the projecting portion of the light-transmissive member.