Fluorescent Resin Application Control for LED Chromaticity
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Solution Overview
Problem
Conventional manufacturing methods for light-emitting devices result in variations in chromaticity due to changes in the concentration of fluorescent particles over time, leading to inconsistent light emission.
Innovation Solution
A method and apparatus that measure the concentration of fluorescent particles in the resin and adjust the application amount based on reference data to maintain constant chromaticity, using a controller and correction apparatus to ensure precise application of fluorescent resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a constant weight of fluorescent resin is discharged from the air dispenser, then the manufacturing process is simple and fast, but the chromaticity of the manufactured light-emitting device varies
Solution Approach 1:
The patent implements a feedback control system where the concentration of fluorescent particles in the resin is continuously measured by a concentration measurement unit. The control unit receives this measurement and adjusts the discharge amount of fluorescent resin from the applicator accordingly. This closed-loop feedback mechanism ensures that even though the discharge speed remains high, the actual amount of fluorescent particles applied is precisely controlled to maintain constant chromaticity, thereby resolving the contradiction between manufacturing speed and chromaticity consistency.
Solution Approach 2:
The patent changes the control parameter from fixed weight discharge to concentration-based variable discharge. Instead of discharging a constant weight of resin regardless of particle concentration, the system now varies the discharge amount based on real-time concentration measurements. When particle concentration is high, less resin is discharged; when concentration is low, more resin is discharged. This dynamic parameter adjustment maintains consistent chromaticity while preserving high manufacturing productivity.
2Device complexity
If the concentration of fluorescent particles is not monitored, then the manufacturing process is simple, but the chromaticity varies due to concentration changes over time
Solution Approach 1:
The patent introduces a concentration measurement unit that continuously monitors the fluorescent particle concentration in the resin and feeds this information back to the control unit. This feedback mechanism enables real-time detection of concentration variations and automatic adjustment of the discharge amount, maintaining constant chromaticity without significantly complicating the overall manufacturing process. The added complexity is minimal and focused only on the measurement and control aspects.
Solution Approach 2:
The patent replaces manual or mechanical weight-based discharge control with an automated concentration-based control system. Instead of relying on mechanical timing or fixed-weight mechanisms, the system uses optical or sensor-based concentration measurement combined with electronic control to adjust the discharge amount. This substitution of mechanical control with sensor-based automated control improves chromaticity consistency while keeping the process relatively simple.
3Manufacturing precision
If the application amount of fluorescent resin is adjusted based on concentration measurement, then the chromaticity becomes constant, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs a feedback control system where concentration measurements automatically trigger adjustments in discharge amount through the control unit. This automated feedback loop eliminates the need for complex manual calculations or multiple control stages, achieving constant chromaticity through a relatively simple closed-loop system that measures concentration and adjusts discharge accordingly.
Solution Approach 2:
The control system performs self-adjustment based on concentration feedback without requiring external intervention. The concentration measurement unit continuously monitors the resin, and the control unit automatically modifies the discharge amount to maintain target chromaticity. This self-service capability reduces the need for complex external control mechanisms or manual adjustments, achieving high precision with minimal added complexity.
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 stabilizes the chromaticity of manufactured light-emitting devices by correcting for concentration variations, reducing the occurrence of defective products with inconsistent color output.
Implementation Method 1
fluorescent particles as wavelength conversion materials (e.g., fluorescent pigment, and fluorescent dye) that are excited by light emitted from the LED chip and emit light different in color from the LED chip
Data Source
AI summary
A method of manufacturing a light-emitting device which includes a light-emitting source is provided by applying, onto the light-emitting source, a fluorescent resin which includes fluorescent particles and is stored in and discharged from an applicator. The method includes measuring a first concentration which is a concentration of the fluorescent particles included in the fluorescent resin discharged from the applicator; and applying, onto the light-emitting source, the fluorescent resin in an application amount determined based on the first concentration which has been measured and reference data which indicates a relationship between a concentration of the fluorescent particles and an application amount of the fluorescent resin that enables the light-emitting device to have constant chromaticity.