Multi-Layer Reflective Coating for High Luminance LED Manufacturing
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Solution Overview
Problem
Current light emitting devices for automotive applications lack the capability to achieve high luminance, which is essential for directional and high-intensity lighting requirements.
Innovation Solution
A method for manufacturing a light emitting device involving a light transmissive member with specific surface configurations and reflective members to enhance luminance, including a light transmissive member with a first upper surface, a lower surface, and lateral surfaces, where the first light reflective member covers the lateral surfaces of the transmissive member, and the second light reflective member covers the first reflective member and the transmissive member's lateral surfaces, along with the light emitting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light transmissive member with oblique surfaces and single reflective coating is used, then the device structure is simpler, but the luminance is insufficient for automotive applications
Solution Approach 1:
The reflective surface is segmented into multiple layers: a first light reflective member covering the oblique lateral surfaces, and a second light reflective member covering the lower surface and peripheral areas. This segmentation allows each layer to perform specific reflective functions, increasing overall luminance while managing structural complexity through functional division.
Solution Approach 2:
The patent transitions from a single-plane reflective surface to a multi-dimensional reflective structure with two distinct reflective members at different positions and orientations. The first reflective member addresses oblique surfaces while the second reflective member addresses the lower surface, creating a three-dimensional light management system that significantly enhances luminance.
2Object-generated harmful factors
If reflective members are applied to cover all lateral surfaces and lower surface, then light leakage is reduced, but manufacturing precision requirements increase
Solution Approach 1:
By dividing the reflective coverage into two separate members (first reflective member for oblique surfaces, second reflective member for lower surface and periphery), the patent reduces the complexity of creating precise borders compared to a single comprehensive reflective coating. Each member has a defined application area that is easier to control during manufacturing.
Solution Approach 2:
The second light reflective member is applied to cover not only the lower surface but also extends to cover the first light reflective member and peripheral areas. This excessive coverage approach ensures complete light containment without requiring extremely precise border definition, as the second member provides a buffer zone that naturally contains any light that might escape from the first member's edges.
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 results in a light emitting device with higher luminance, reduced light leakage, and improved production yield by ensuring clear borders between light emitting and non-emitting areas, thus enhancing the device's ability to project light effectively.
Implementation Method 1
applying a first light reflective member to cover the first lateral surfaces of the light transmissive member
Implementation Method 2
applying a second light reflective member to cover lateral surfaces of the first light reflective member, the second lateral surfaces of the light transmissive member, and a lateral surface of the light emitting element
Data Source
AI summary
A method for manufacturing a light emitting device includes: providing a light emitting element; providing a light transmissive member having a first upper surface, a lower surface, first lateral surfaces, and second lateral surfaces each positioned on an outer side of a corresponding one of the first lateral surfaces; joining the lower surface of the light transmissive member and an upper surface of the light emitting element; applying a first light reflective member to cover the first lateral surfaces of the light transmissive member, and applying a second light reflective member to cover lateral surfaces of the first light reflective member, the second lateral surfaces of the light transmissive member, and a lateral surface of the light emitting element.