Light-Transmissive Member Assembly for Higher LED Light Extraction
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Solution Overview
Problem
Existing light emitting devices face challenges in efficiently extracting light due to luminance differences between the inside and outside of the light exit surface, leading to suboptimal light emission and distribution.
Innovation Solution
A manufacturing method involving a light-shielding frame with convex portions and a light-transmissive member, where a light reflecting resin is applied to cover the convex portions, forming a first light reflecting member that joins the light-shielding frame and light-transmissive member, enhancing light extraction efficiency by reducing voids and improving joint strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional light emitting device structure is used, then the device is simple to manufacture, but light extraction efficiency is poor due to small luminance difference between inside and outside of light exit surface
Solution Approach 1:
The patent applies local quality by creating a light-shielding frame with convex portions at specific locations around the light exit surface. These convex portions are strategically positioned to block stray light paths while maintaining openness in other areas, thereby locally enhancing light extraction efficiency without complicating the overall manufacturing process
Solution Approach 2:
The light-shielding frame is segmented into multiple convex portions rather than being a continuous structure. This segmentation allows selective light blocking in specific directions while maintaining light extraction in other areas, improving overall light extraction efficiency without requiring complete structural enclosure
2Productivity
If the light-shielding frame completely surrounds the light exit surface, then light extraction is maximized, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
Instead of complete surrounding, the invention uses localized convex portions at specific positions on the light-shielding frame. This local approach achieves effective light extraction enhancement without the structural complexity of a fully enclosed design
Solution Approach 2:
The patent applies partial action by using discrete convex portions rather than complete surrounding. This partial shielding approach provides sufficient light extraction improvement while avoiding the excessive structural complexity and manufacturing difficulty of a fully enclosed frame
3Ease of manufacture
If voids are present in the joint between light-transmissive member and light-shielding frame, then manufacturing is easier, but light extraction efficiency decreases
Solution Approach 1:
The convex portions are pre-formed on the light-shielding frame before assembly with the light-transmissive member. This preliminary structuring ensures proper alignment and contact during assembly, eliminating voids without complicating the assembly process itself
Solution Approach 2:
The convex portions act as intermediaries that facilitate proper contact between the light-transmissive member and light-shielding frame. By providing predetermined contact points, they ensure complete bonding without voids while maintaining ease of 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
The method achieves a significant increase in luminance difference between the inside and outside of the light exit surface, efficiently extracting light from the light emitting elements, resulting in improved light distribution and emission patterns suited for automotive lighting applications.
Implementation Method 1
supplying a light reflecting resin to the second main surface of the light-shielding frame so that the light reflecting resin comes into contact with the convex portion
Data Source
AI summary
A method for manufacturing a light emitting device includes: preparing a light-shielding frame defining a through-hole, and having at least one convex portion; supplying a light reflecting resin so that the convex portion is at least partially covered; preparing a light-transmissive member having a first surface with an outer periphery smaller than an inner periphery of the first main surface, a first side surface contiguous with the first surface, a second side surface located outside of the first side surface, and a third surface contiguous with the first and second side surfaces; bringing the third surface into contact with the convex portion, or with the light reflecting resin in contact with the convex portion, so that the light reflecting resin is disposed between the first side surface and an inside surface of the light-shielding frame; curing the light reflecting resin; and joining light emitting elements and the light-transmissive member.