Light Emitting Device Chromaticity Control via Element Segregation
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Solution Overview
Problem
Existing light emitting devices face challenges in achieving a desired luminescent chromaticity with high yield, as they often require combining light emitting elements with deviated chromaticity, which can be inefficient and reduce manufacturing yield.
Innovation Solution
A method involving a wafer with a substrate and light emitting structure layer, where a phosphor layer is formed and applied, followed by dividing the wafer to create light emitting elements. These elements are then classified based on luminescent chromaticity, with those outside the required range being combined to achieve the desired chromaticity in the final device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light emitting elements with deviated chromaticity are combined to achieve desired luminescent chromaticity, then the desired chromaticity can be obtained, but the manufacturing yield decreases
Solution Approach 1:
The patent applies preliminary action by measuring and classifying the luminescent chromaticity of light emitting elements before assembling them into devices. This advance classification allows elements to be sorted into appropriate groups (first group with chromaticity within required range, second group with chromaticity outside required range) before final device assembly, enabling efficient matching and combination to achieve desired chromaticity while maximizing yield
Solution Approach 2:
The patent utilizes parameter changes by adjusting the chromaticity parameters of the final light emitting device through selective combination of individual elements. By measuring the luminescent chromaticity of each element and strategically combining elements from both the first and second groups, the final device achieves the desired chromaticity parameter even when individual elements have deviated chromaticity
2Productivity
If light emitting elements are classified and combined based on luminescent chromaticity, then manufacturing yield is improved, but the process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the light emitting elements into distinct groups based on their luminescent chromaticity measurements. Elements are segmented into a first group with chromaticity within the required range and a second group with chromaticity outside the required range. This segmentation simplifies the subsequent assembly process by providing clear categories for element selection and combination
Solution Approach 2:
The patent implements feedback by measuring the luminescent chromaticity of light emitting elements and using this measurement information to guide the classification and combination process. The measured chromaticity values provide feedback that determines which elements should be grouped together to achieve the desired final chromaticity, creating a closed-loop manufacturing approach
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 method allows for accurate control of luminescent chromaticity and enhances manufacturing yield by enabling the production of light emitting devices with the desired chromaticity, even when individual elements have chromaticity outside the required range.
Implementation Method 1
forming a phosphor layer comprising a resin and a phosphor so as to cover a surface of the wafer on a side of the substrate
Data Source
AI summary
A method for manufacturing a light emitting device includes providing a wafer including a substrate, a light emitting structure layer and a plurality of electrodes, forming a phosphor layer so as to cover a surface of the wafer on a side of the substrate, dividing the wafer and the phosphor layer so as to form a plurality of light emitting elements, measuring a luminescent chromaticity of the plurality of light emitting elements so as to classify into a first light emitting element having a luminescent chromaticity within a required chromaticity range and a second light emitting element having a luminescent chromaticity outside the required chromaticity range, and forming a second light emitting device that includes the plurality ones of the second light emitting element and the luminescent chromaticity within the required chromaticity range by using the second light emitting element.