Light-Emitting Module Wire-Bond Layout for Protected Connections
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Solution Overview
Problem
Existing light-emitting devices face challenges in facilitating electrical connections between light sources and mounting members, particularly in terms of efficient wire bonding techniques, which can be cumbersome and prone to mechanical stress.
Innovation Solution
A light-emitting device design featuring a support substrate with exposed wire-connecting portions and a light-reflective member with recesses to accommodate resin coverage, allowing for easier wire connection and improved mechanical stability, along with a manufacturing method that includes disposing resin members to protect and secure the wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonding technique is employed to electrically connect the light source and the mounting member, then electrical connection is achieved, but the connection is cumbersome and prone to mechanical stress
Solution Approach 1:
The support substrate is pre-formed with protruding portions that expose wire-connecting portions before the light-emitting units are mounted. This preliminary preparation of connection interfaces simplifies the subsequent wire bonding process and reduces operational complexity during assembly.
Solution Approach 2:
The protruding portions of the support substrate serve as intermediary structures that extend beyond the light-reflective member to provide accessible wire-connecting portions. This intermediary structure facilitates easier wire connection while the light-reflective member remains intact, reducing mechanical stress on the connection process.
2Shape
If the light-reflective member covers the wire-connecting portions, then appearance is improved, but wire connection becomes difficult
Solution Approach 1:
The support substrate is segmented into distinct functional regions: areas covered by the light-reflective member for aesthetic purposes, and protruding portions that expose wire-connecting portions for operational access. This segmentation allows simultaneous achievement of good appearance and ease of wire connection.
Solution Approach 2:
Different regions of the support substrate have different properties: the covered regions provide aesthetic appearance while the protruding regions provide accessible connection points. This local differentiation of quality allows the light-reflective member to cover most areas for appearance while leaving specific areas exposed for wire connection.
3Reliability
If resin is applied to protect the wires, then mechanical protection is improved, but the structure becomes more complex
Solution Approach 1:
The resin member integrates multiple functions into a single component: it protects the wires mechanically, fills the recess in the light-reflective member, and provides structural support. This merging of functions reduces overall structural complexity compared to using separate components for each function.
Solution Approach 2:
The resin member serves multiple purposes simultaneously: wire protection, recess filling, and structural support. This multi-functionality reduces the number of separate components needed, thereby simplifying the overall device structure while improving mechanical protection.
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 design enhances the ease of electrical connection and mechanical protection of wires, reducing the risk of mechanical stress and improving the appearance and reliability of the light-emitting device.
Implementation Method 1
a light-reflective member covering the plurality of light-emitting units
Data Source
AI summary
A manufacturing method of a light-emitting device includes: providing a light source comprising: a plurality of light-emitting units, a support substrate comprising, on a first upper surface: a plurality of first terminal portions electrically connected with respective ones of the light-emitting units, each comprising a plurality of terminals, and one or more first wire-connecting portions, and a light-reflective member covering the plurality of light-emitting units and comprising a recess in which one or more first wire-connecting portions are exposed from the light-reflective member; providing a control unit comprising, on a second upper surface: a first region where the light source is to be disposed, and one or more second wire-connecting portions disposed in a second region other than the first region; disposing the light source in the first region; and connecting the first and second wire-connecting portions with a first wire.