Light-guiding supporting member for LED luminance contrast
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Solution Overview
Problem
Existing light-emitting devices face challenges in efficiently extracting light due to differences in luminance between the inside and outside of the light exit surface, leading to reduced light extraction efficiency and potential voids in the manufacturing process.
Innovation Solution
A method involving a light-shielding frame with narrow portions and a light-reflective resin application to form a light-guiding supporting member, where the light-transmissive member is pressed to allow the resin to flow into the gap between the frame and the transmissive member, creating a reflective member that enhances light extraction while preventing voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light-shielding frame is used to increase luminance contrast between inside and outside of light exit surface, then light extraction efficiency is improved, but manufacturing complexity increases due to multiple components and assembly steps
Solution Approach 1:
The patent combines the light-shielding frame and light-transmissive member into a single integrated light-guiding supporting member. The light-transmissive member is positioned within the opening of the light-shielding frame to form an integrated structure that maintains the luminance contrast effect while simplifying manufacturing by reducing the number of separate components and assembly steps.
2Strength
If light-reflective resin is applied to bond components, then bonding strength is improved, but air bubbles or voids may be trapped reducing reliability
Solution Approach 1:
The patent applies the light-reflective resin to the light-shielding frame before positioning the light-transmissive member. This preliminary application allows the resin to be evenly distributed and ensures that when the components are assembled, the resin is already in place to fill gaps and prevent air bubble entrapment, thereby maintaining bonding strength while improving reliability.
3Strength
If the light-transmissive member is pressed to allow resin to flow into gaps, then bonding is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies the light-reflective resin specifically to the light-shielding frame at the bonding interface before assembling the light-transmissive member. This localized resin application ensures that the resin is precisely positioned where bonding is needed, allowing the pressing operation to effectively fill gaps and create strong bonds without requiring extremely high overall alignment precision across the entire component 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
This approach results in a light-emitting device with improved luminance contrast and reduced voids, enhancing light extraction efficiency and bonding strength, thus manufacturing a device with desired optical properties.
Implementation Method 1
applying a light-reflective resin on the light-shielding frame
Implementation Method 2
providing a light-transmissive member having a plate shape
Data Source
AI summary
A method of manufacturing a light-emitting device includes: mounting a light-emitting element on a mounting board; placing a light-shielding frame on a sheet, the light-shielding frame defining an opening and comprising at least one narrow portion having a width that is smaller than that of another portion of the light-shielding frame in a top view; applying a light-reflective resin on at least the narrow portion of the light-shielding frame; forming a light-guiding supporting member; and bonding the second surface of a light-transmissive member of the light-guiding supporting member to an upper surface of the light-emitting element so as to fix the light-guiding supporting member on or above the light-emitting element.