Optical Device Conductive Layer Segmentation for Adhesion Prevention
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Solution Overview
Problem
Conventional semiconductor light-emitting devices face issues with optical elements being desorbed from the conductive layer, leading to potential cracks and stress concentration, which can result in the optical elements being detached from their intended positions.
Innovation Solution
The optical device incorporates a conductive layer with specific sections and portions, an insulating layer that overlaps with certain conductive sections, and a sealing resin part to cover the optical elements, preventing adhesion between the conductive layer and the sealing resin, thus minimizing the risk of optical elements being desorbed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductive layer is directly exposed without insulating layer coverage, then the optical element can be positioned over the conductive layer, but the sealing resin may adhere to the conductive layer causing optical element desorption
Solution Approach 1:
The conductive layer is segmented into multiple conductive sections (first conductive section, second conductive section, third conductive section) with specific spacing relationships. This segmentation allows the insulating layer to be selectively positioned over certain sections while leaving others exposed, preventing unwanted adhesion between the sealing resin and conductive layer while maintaining optical element positioning capability
Solution Approach 2:
The insulating layer is applied locally over specific conductive sections rather than uniformly across the entire conductive layer. The first insulating part is formed over the first conductive portion, creating localized insulation zones that prevent adhesion only where needed, while other areas remain conductive for optical element positioning
2Reliability
If the insulating layer completely covers the conductive layer, then adhesion between sealing resin and conductive layer is prevented, but optical element positioning over the conductive layer becomes difficult
Solution Approach 1:
The insulating layer is divided into multiple insulating parts (first insulating part, second insulating part, third insulating part) that correspond to different conductive sections. This segmentation allows selective insulation of specific areas while leaving other areas exposed for optical element positioning
Solution Approach 2:
Different regions of the conductive layer have different insulation properties - some areas are covered by the insulating layer to prevent adhesion, while other areas remain exposed to facilitate optical element positioning. The first insulating part is positioned over the first conductive portion, creating localized functional zones
3Area of stationary object
If the conductive sections are placed close together, then the device area is reduced, but stress concentration increases leading to potential cracks
Solution Approach 1:
The conductive sections are arranged with asymmetric spacing relationships - the first conductive section and second conductive section are spaced apart in a first direction, while the second conductive section and third conductive section are spaced apart in a second direction that intersects with the first direction. This asymmetric, multi-directional spacing optimizes both area utilization and stress distribution
Solution Approach 2:
The spacing between conductive sections is defined in multiple directions (first direction and second direction that intersect), transforming a one-dimensional spacing problem into a two-dimensional arrangement. This multi-dimensional spacing strategy reduces stress concentration while maintaining compact device area
Data Source
AI summary
An optical device includes a substrate, a conductive layer formed over the substrate, an insulating layer formed over the conductive layer, a first optical element disposed over the conductive layer, and a sealing resin part configured to cover the first optical element. The conductive layer includes a first conductive section, a second conductive section spaced apart from the first conductive section, and a first conductive portion extending in a first direction from the first conductive section. The first conductive portion is spaced apart from the second conductive section in a second direction intersecting with the first direction, and the insulating layer includes a first insulating part formed over the first conductive portion, and the first insulating part includes a portion overlapping with the second conductive section in the first direction.