LED Color Correction via Two-Stage Phosphor Resin Coating
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Solution Overview
Problem
Light emitting devices produced through the same process exhibit color coordinate dispersion due to process margins, leading to defective products being discarded, despite being fabricated with the same kind and concentration of phosphors.
Innovation Solution
A method involving the formation of a first resin with phosphors on a light emitting diode chip, allowing it to settle, measuring color coordinates, and correcting deviations by mixing a second resin with the first resin, which may contain different or the same kind of phosphors, to achieve desired color coordinates within a target bin, followed by curing both resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light emitting devices are produced through the same process with the same kind and concentration of phosphors, then manufacturing consistency is improved, but color coordinate dispersion occurs due to process margins
Solution Approach 1:
The patent adjusts phosphor concentration parameters to compensate for process variations. By carefully controlling and optimizing the concentration of phosphors in the resin, the invention compensates for color coordinate dispersion caused by process margins, ensuring that devices produced through the same process maintain consistent color coordinates within target bins
Solution Approach 2:
The patent performs preliminary color coordinate measurement and adjustment during the manufacturing process. By measuring color coordinates of individual devices and adjusting phosphor distribution before final packaging, the invention prevents defective products from being discarded and ensures all devices meet quality standards
2Manufacturing precision
If color coordinates are corrected by sorting and selecting individual devices, then product quality is improved, but productivity decreases due to increased processing time
Solution Approach 1:
The patent performs preliminary color coordinate correction during the phosphor coating process itself. By adjusting phosphor concentration and distribution before device completion, the invention achieves color coordinate accuracy without requiring time-consuming post-manufacturing sorting and selection, thereby maintaining high productivity
Solution Approach 2:
The patent enables self-correction of color coordinates through controlled phosphor distribution. The manufacturing process itself incorporates the correction mechanism by varying phosphor concentration in different regions or batches, eliminating the need for separate correction operations and external sorting processes
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 improves the yield of light emitting devices by correcting color coordinates within a target range, simplifying the process by allowing the first resin to settle and measure color coordinates before curing, and enabling the use of different phosphor concentrations to achieve desired color coordinates.
Implementation Method 1
a wavelength conversion section disposed on the light emitting diode chip, wherein the wavelength conversion section includes first phosphors and second phosphors mixed with a transparent resin
Data Source
AI summary
A method of fabricating a light-emitting device including the steps of forming a first resin including a phosphor on a light-emitting diode chip mounted on a package body, measuring color coordinates of light emitted by combination of the light-emitting diode chip and the phosphor, correcting the color coordinates by forming a second resin on the first resin, and curing the first resin and the second resin after correcting the color coordinates, in which the first resin is not fully cured before measuring and correcting the color coordinates.