Resin Coating Pulse Spraying for LED Mounting Release

Solution Overview

Problem

Existing light emitting devices face issues with adhesion to cover tapes and poor release during mounting due to tackiness, leading to inefficiencies in the manufacturing process.

Innovation Solution

A method involving a pulse spraying technique to deposit a resin mixture containing a thixotropy imparting agent on a light emitting element, forming a light transmissive member with a wavelength conversion layer and an outermost layer that has protrusions and recesses, reducing adhesion and tackiness, thereby minimizing adhesion to cover tapes and improving release during mounting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a resin layer is formed on the light emitting element, then light transmission is achieved, but adhesion to cover tape increases and release during mounting becomes poor

Engineering Contradiction:

Improvelight transmissionVSAvoidrelease during mounting

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by creating a resin layer with non-uniform filler distribution. The filler concentration varies through the thickness of the resin layer, with higher concentration near the light emitting element and lower concentration toward the upper surface. This gradient structure provides different properties at different locations: strong adhesion to the light emitting element and reduced adhesion to the cover tape, thereby solving the contradiction between light transmission reliability and ease of manufacture.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs parameter changes by modifying the filler concentration parameter throughout the resin layer thickness. By controlling the filler concentration to decrease from the lower surface to the upper surface, the resin layer achieves optimized optical properties for light transmission while simultaneously reducing surface tackiness to improve release characteristics during mounting operations.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If filler concentration is increased to improve light transmission, then adhesion to cover tape increases, but release becomes poor

Engineering Contradiction:

Improvelight transmissionVSAvoidmounting efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies local quality by creating a resin layer with non-uniform filler distribution. The filler concentration varies through the thickness of the resin layer, with higher concentration near the light emitting element and lower concentration toward the upper surface. This gradient structure provides different properties at different locations: strong adhesion to the light emitting element and reduced adhesion to the cover tape, thereby solving the contradiction between light transmission reliability and ease of manufacture.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs parameter changes by modifying the filler concentration parameter throughout the resin layer thickness. By controlling the filler concentration to decrease from the lower surface to the upper surface, the resin layer achieves optimized optical properties for light transmission while simultaneously reducing surface tackiness to improve release characteristics during mounting operations.

Inventive Principle:

Principle #35Parameter changes

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 effectively reduces adhesion to cover tapes and improves the release process during mounting, enhancing the manufacturing efficiency of light emitting devices by incorporating a thixotropy imparting agent and forming a surface with specific roughness for reduced tackiness.

Implementation Method 1

The resin mixture includes a thixotropy imparting agent

Methodology Applied

Scientific EffectThixotropy: Thixotropy

Implementation Method 2

spraying a resin mixture onto a light emitting element using a pulse spraying method to deposit the resin mixture on the light emitting element

Methodology Applied

Scientific EffectPulse spraying: Fluid Spray

Implementation Method 3

The resin mixture is cured to form a light transmissive member

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS9882103B2Method for producing light emitting device

Publication Date: 2018.01.30 NICHIA CORP

AI summary

A method for producing a light emitting device includes spraying a resin mixture onto a light emitting element using a pulse spraying method to deposit the resin mixture on the light emitting element. The resin mixture includes a thixotropy imparting agent. The resin mixture is cured to form a light transmissive member via which light emitted from the light emitting element is to transmit to an outside of the light emitting device.