Hybrid LED Module with Patterned Phosphor Encapsulation
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Solution Overview
Problem
Conventional chip-on-board LED modules suffer from inefficiencies due to wavelength conversion materials absorbing unwanted light ranges, leading to reduced light output efficiency.
Innovation Solution
The use of different wavelength conversion materials or concentrations of materials to encapsulate light emitting elements of various colors, with phosphor-free encapsulants for elements not intended for conversion and phosphor-containing encapsulants for elements that require wavelength conversion, optimizing light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If wavelength conversion material is used to convert light from light emitting elements, then desired color output is achieved, but light output efficiency is reduced due to absorption of unwanted light ranges
Solution Approach 1:
The patent applies different wavelength conversion materials or different concentrations of wavelength conversion materials to different regions or sets of light emitting elements within the same module. This allows each region to be optimized for its specific light emitting elements, converting only the unwanted wavelengths while preserving the desired wavelengths, thereby resolving the contradiction between achieving desired color output and maintaining light output efficiency
Solution Approach 2:
The patent divides the light emitting elements into different sets or groups, with each set having its own dedicated wavelength conversion material or concentration. This segmentation allows independent optimization of each set, preventing the universal absorption of unwanted light ranges across the entire module and thus maintaining overall light output efficiency while achieving desired color outputs
2Illumination intensity
If phosphor-containing encapsulant is used for all light emitting elements, then wavelength conversion is achieved, but light absorption losses increase
Solution Approach 1:
The patent implements local quality by applying phosphor-containing encapsulant only to specific light emitting elements that require wavelength conversion, while leaving other light emitting elements with phosphor-free encapsulant. This selective application ensures that wavelength conversion occurs only where needed, minimizing unnecessary light absorption losses while still achieving the required wavelength converted light output
Solution Approach 2:
The patent extracts the wavelength conversion function from a universal encapsulant and applies it selectively only to the light emitting elements that require it. By taking out the phosphor material from the general encapsulant and applying it locally, the system avoids the energy loss of absorbing light that doesn't need conversion while maintaining the beneficial wavelength conversion where required
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 enhances light output efficiency by minimizing unwanted absorption and allowing for precise control of light output ratios and patterns, improving the performance of hybrid LED modules.
Implementation Method 1
wavelength conversion material may be used to convert at least a portion of the light emitted by the light emitting elements to different wavelengths
Implementation Method 2
each phosphor may efficiently absorb light of a first range of wavelengths and emit light of a desired second range of wavelengths
Data Source
AI summary
Light modules and methods of forming light modules are disclosed. A light module includes a first plurality and a second plurality of light emitting elements configured to emit, respectively, a first light and a second light, and both arranged on a substrate. An encapsulation layer is disposed over the first and second plurality of the light emitting elements, and a wavelength converting element is dispersed in the encapsulation layer. A concentration of the wavelength converting element in the encapsulation layer varies, is larger over the first plurality of light emitting elements and is smaller over the second plurality of light emitting elements.