Lighting Device Insulation Layer Segmentation

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Solution Overview

Problem

Conventional lighting devices with alumina or ceramic ink layers on metal plates are prone to cracking during the dicing process, leading to potential electrical insulation deterioration.

Innovation Solution

A lighting device design featuring a metal plate with an electrical insulation layer smaller than the metal plate's outline, positioned on its upper surface, and light-emitting elements mounted on this layer, with connecting electrodes arranged to prevent cracking and ensure electrical connectivity, and the insulation layer is designed to be buried with the light-emitting elements for added stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an alumina layer or ceramic ink layer is entirely layered on the surface of a metal plate, then electrical insulation is provided, but the insulation layer is prone to cracking during the dicing process

Engineering Contradiction:

Improveelectrical insulation integrityVSAvoidcrack-free insulation layer

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent divides the insulation layer into two distinct parts: a first insulation layer that extends to the peripheral edge of the metal plate, and a second insulation layer that is smaller and positioned centrally. This segmentation allows the first layer to provide edge protection while the second layer accommodates the light-emitting element, preventing stress concentration and cracking during dicing operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different insulation layer configurations to different regions of the metal plate. The first insulation layer covers the peripheral edge area to prevent cracking during dicing, while the second, smaller insulation layer is positioned centrally to accommodate the light-emitting element. This local differentiation optimizes both manufacturing reliability and electrical insulation performance.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If the electrical insulation layer is smaller than the metal plate outline, then cracking is prevented during dicing, but the peripheral edge insulation coverage is reduced

Engineering Contradiction:

Improvecrack-free insulation layerVSAvoidinsulation layer coverage area

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The patent segments the insulation coverage into two functional zones: the first insulation layer extends to the peripheral edge to prevent cracking during dicing, while the second, smaller insulation layer is positioned centrally to accommodate the light-emitting element. This segmentation ensures adequate edge coverage for manufacturing reliability while providing centralized insulation for electrical functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent resolves the area coverage issue by transitioning from a single-layer two-dimensional solution to a multi-layer three-dimensional configuration. The first insulation layer provides peripheral coverage, while the second insulation layer provides central coverage, together achieving comprehensive insulation without requiring a single large continuous layer that would be prone to cracking.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of operation

If light-emitting elements are mounted on the electrical insulation layer, then electrical connection is enabled, but the insulation layer may crack under stress during manufacturing

Engineering Contradiction:

Improveelectrical connectivityVSAvoidinsulation layer stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent segments the insulation layer into a first layer extending to the peripheral edge and a second smaller layer positioned centrally where the light-emitting element is mounted. This segmentation isolates the stress concentration area to the second layer, allowing the first layer to maintain structural integrity and prevent cracking during dicing operations while still enabling electrical connectivity through the second layer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first insulation layer acts as a cushioning structure that prevents stress from propagating to the edges during dicing operations. By positioning the second, smaller insulation layer centrally and allowing it to be smaller than the first layer, the design creates a buffer zone that absorbs manufacturing stresses before they can reach the peripheral edges, thereby preventing cracks.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS8835944B2Lighting device

Publication Date: 2014.09.16 CITIZEN ELECTRONICS CO LTD

AI summary

In a first aspect of the present invention, a lighting device including a metal plate, an electrical insulation layer that is smaller in size than an outline of the metal plate and arranged on an upper surface of the metal plate, a light-emitting element mounted on the electrical insulation layer, and a first connecting electrode and a second connecting electrode electrically connected to the light-emitting element and arranged on the electrical insulation layer.