Light Emitting Device Support Member for High-Density Positioning

Solution Overview

Problem

Current light emitting devices face challenges in precisely positioning a high density of light emitting surfaces due to limitations in structural design and manufacturing methods.

Innovation Solution

A light emitting device comprising element structural bodies with a substrate, a light emitting element, and a light-transmissive member, covered by a support member and covering members, which allows for precise alignment and high-density positioning of light emitting surfaces, along with a method of manufacturing that involves aligning through holes in the support member with holes on a module substrate for accurate mounting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple light emitting surfaces are disposed in high density, then light distribution efficiency is improved, but positioning precision deteriorates

Engineering Contradiction:

Improvelight emitting surface densityVSAvoidpositioning precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The support member is divided into multiple support portions, each corresponding to individual element structural bodies. This segmentation allows independent positioning control for each light emitting element, enabling high-density arrangement while maintaining precise positioning through localized support structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support member acts as an intermediary between the substrate and the mounting board, providing through-holes that align with mounting board holes. This intermediary structure enables precise positioning by establishing a reference framework that guides the mounting process and ensures accurate alignment of high-density light emitting surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If multiple light emitting surfaces are disposed in high density, then light distribution efficiency is improved, but structural stability deteriorates

Engineering Contradiction:

Improvelight emitting surface densityVSAvoidstructural stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The support member is divided into multiple support portions, each corresponding to individual element structural bodies. This segmentation allows independent positioning control for each light emitting element, enabling high-density arrangement while maintaining precise positioning through localized support structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support member acts as an intermediary between the substrate and the mounting board, providing through-holes that align with mounting board holes. This intermediary structure enables precise positioning by establishing a reference framework that guides the mounting process and ensures accurate alignment of high-density light emitting surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If covering member is used to cover lateral surfaces, then protection is improved, but warping resistance deteriorates

Engineering Contradiction:

ImproveprotectionVSAvoidwarping resistance

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The support member provides localized rigid support at specific positions (through-holes) rather than uniform support across the entire structure. This local quality approach allows the covering member to perform its protective function while the strategically positioned support portions prevent warping by providing targeted structural reinforcement where needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The device combines the covering member (for protection) with the support member (for structural stability). This composite structure integrates two functional components with different properties - the covering member provides environmental protection while the rigid support member with through-holes provides warping resistance and positioning accuracy.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11655947B2Light emitting device, light emitting module, and method of manufacturing light emitting module

Publication Date: 2023.05.23 NICHIA CORP

AI summary

A light emitting device includes: a plurality of element structural bodies, each including: a substrate, a light emitting element mounted on or above the substrate, and a light-transmissive member disposed on or above the light emitting element, wherein at least three of the plurality of element structural bodies are disposed along a first direction; a first covering member that covers lateral surfaces of the substrate, the light emitting element, and the light-transmissive member of each of the plurality of element structural bodies; and a support member that covers a lateral surface of the first covering member, wherein at least a portion of the support member is disposed lateral to the plurality of element structural bodies and extends along the first direction. A rigidity of the support member is greater than a rigidity of the first covering member.