LED Chip Raised Border Phosphor Resin Retention
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Solution Overview
Problem
Current light emitting diode (LED) structures, particularly those using the mini-glob technique, suffer from high variation in color output and blue light leakage due to the difficulty in positioning large phosphor particles, leading to inefficient white light emission and increased fabrication costs.
Innovation Solution
A light emitting diode structure featuring a raised border around the perimeter of the top surface, filled with a polymer resin containing phosphor particles, which allows for a thicker resin edge and better retention of phosphor particles, minimizing blue light leakage and enhancing color uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If large phosphor particles are used in the mini-glob technique, then white light conversion efficiency is improved, but positioning precision deteriorates and blue light leakage increases
Solution Approach 1:
The invention divides the phosphor-containing resin into multiple discrete globules, each containing phosphor particles of appropriate size for efficient light conversion. This segmentation allows large phosphor particles to be contained within individual globules rather than requiring precise positioning across the entire LED surface, thus maintaining conversion efficiency while reducing positioning complexity.
Solution Approach 2:
The invention transitions from a two-dimensional planar phosphor layer to a three-dimensional array of resin globules with varying sizes and positions. This dimensional change allows phosphor particles to be distributed volumetrically within each globule, improving light conversion while the globule structure itself provides the positioning function, eliminating the need for precise lateral positioning of individual particles.
2Illumination intensity
If large phosphor particles are used, then yellow light emission is enhanced, but blue light leakage increases due to poor retention
Solution Approach 1:
The invention nests phosphor particles within encapsulating resin globules, creating a hierarchical structure where particles are contained within a matrix that provides both structural support and optical confinement. This nesting ensures that large phosphor particles remain retained within the resin globules, converting blue light to yellow light efficiently without allowing blue light to leak through gaps between particles.
Solution Approach 2:
The invention uses composite resin globules containing phosphor particles dispersed within the resin matrix. This composite structure combines the light-converting properties of large phosphor particles with the retaining and optically homogeneous properties of the resin, achieving both strong yellow light emission and effective prevention of blue light leakage simultaneously.
3Object-generated harmful factors
If the resin layer is made thicker to retain phosphor particles, then blue light leakage is reduced, but fabrication complexity increases
Solution Approach 1:
The invention employs self-assembled resin globules that form through controlled drying or curing processes, where the globule size and distribution emerge dynamically during fabrication rather than requiring precise pre-positioning. This dynamic formation process simplifies fabrication by allowing the structure to self-organize into the desired configuration with appropriate thickness for retaining phosphor particles and preventing blue light leakage.
Solution Approach 2:
The resin globules serve multiple functions simultaneously: they contain and retain the phosphor particles, provide the necessary thickness to prevent blue light leakage, and maintain optical homogeneity. This multi-functionality reduces fabrication complexity by eliminating the need for separate structures or processes to address each of these requirements independently.
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 solution achieves improved color uniformity and reduced blue light leakage, resulting in a more efficient conversion of blue light to yellow, thereby producing a consistent white output with reduced fabrication complexity and costs.
Implementation Method 1
phosphor particles in the resin that convert the frequencies emitted by the active portion
Data Source
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AI summary
A method of tuning a light-emitting diode (27) is provided, comprising the steps of: measuring the wavelength and/or radiant flux produced by the light-emitting diode, and thereafter covering the diode with an amount of phosphor (34) combined with a polymer resin (33) that produces a selected colour based upon the measured colour and the added phosphor in the resin.