Coated Lumiphoric Particles for Graded LED Wavelength Conversion
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Solution Overview
Problem
Existing LED packages face challenges in producing high-quality light with desired emission characteristics while maintaining high light emission efficiency, particularly in achieving improved optical, mechanical, and thermal characteristics.
Innovation Solution
The integration of lumiphoric particle structures within wavelength conversion elements, where pre-formed coatings on lumiphoric particles diffuse into host materials during heat treatment to form graded material structures, enhancing optical, mechanical, and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If lumiphoric particles are integrated into wavelength conversion elements, then light emission efficiency is improved, but manufacturing complexity increases due to coating and firing processes
Solution Approach 1:
Coatings are pre-formed on lumiphoric particles before integration into the wavelength conversion element. This preliminary action ensures proper coating application and simplifies the subsequent manufacturing process by eliminating the need for complex in-situ coating procedures.
Solution Approach 2:
Heat treatment is applied to diffuse coating materials within the wavelength conversion element, transforming the physical and chemical properties of the materials. This parameter change (temperature increase during firing) enables the formation of graded material structures that improve optical, mechanical, and thermal characteristics.
2Illumination intensity
If coatings are pre-formed on lumiphoric particles, then optical characteristics are improved, but manufacturing time increases due to additional coating steps
Solution Approach 1:
Coatings are applied to lumiphoric particles in advance, before the particles are integrated into the final product. This allows for optimized coating processes to be used and ensures high optical quality, while the subsequent integration process benefits from the particles already being prepared.
Solution Approach 2:
The coating formation and particle integration processes are combined into a single manufacturing workflow. Coated particles are suspended in host material and fired together, merging multiple steps into a more efficient integrated process.
3Stability of the object's composition
If heat treatment is applied to diffuse coating materials, then material homogeneity is improved, but energy consumption increases
Solution Approach 1:
Controlled heat treatment is applied to achieve the desired diffusion of coating materials. By carefully managing the temperature parameters and treatment duration, the process achieves optimal material homogeneity while minimizing energy consumption. The firing process transforms the physical state of materials to enable proper diffusion and integration.
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
This approach results in LED packages with improved optical, mechanical, and thermal characteristics, leading to enhanced light emission efficiency and reliability, suitable for various applications including high-power and automotive uses.
Implementation Method 1
firing the host material with the one or more lumiphoric particles such that the first material of the coating radially diffuses into the host material around the one or more lumiphoric particles
Implementation Method 2
Heat treatments associated with firing wavelength conversion elements may diffuse coating materials within wavelength conversion elements to form graded material structures
Data Source
AI summary
Solid-state lighting devices including light-emitting diodes (LEDs) and more particularly lumiphoric particle structures in wavelength conversion elements for LEDs and related methods are disclosed. Lumiphoric particle structures include coatings that provide improved optical, mechanical, and/or thermal characteristics when distributed within host materials of wavelength conversion elements. Coatings are pre-formed on lumiphoric particles before the lumiphoric particles are integrated with wavelength conversion elements. Heat treatments associated with firing wavelength conversion elements may diffuse coating materials within wavelength conversion elements to form graded material structures for further improvements to optical, mechanical, and/or thermal characteristics.