Wavelength-Conversion Material Integration in LED Dies
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Solution Overview
Problem
The high cost and complexity of LED-based lighting systems, particularly in broad-area general lighting applications, due to the need for multiple LEDs and active current control systems, as well as challenges in uniform phosphor integration for white light production, which affects efficiency and reliability.
Innovation Solution
A method involving semiconductor dies coated with a polymeric binder containing wavelength-conversion materials like phosphors, forming a composite wafer that is then separated into discrete portions with uniform binder thickness, allowing for uniform and cost-effective integration of phosphors with LEDs, eliminating the need for complex light-mixing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple packaged LEDs operating at different wavelengths are used to generate white light, then the desired light intensity and color can be achieved, but the system cost and complexity increase due to multiple LEDs and active current control systems
Solution Approach 1:
The patent combines multiple wavelength-emitting LEDs into a single integrated LED structure with multiple active regions, eliminating the need for separate packaged LEDs and their individual control circuits. This merging approach maintains white light generation capability while significantly reducing system complexity and cost.
Solution Approach 2:
The integrated LED is designed to perform multiple functions simultaneously - generating multiple wavelengths (red, green, blue) within a single device, thereby replacing what would traditionally require multiple separate LEDs and their associated control systems.
2Illumination intensity
If multiple packaged LEDs operating at different wavelengths are used to generate white light, then the desired light intensity can be achieved, but the system cost increases due to multiple LEDs and control systems
Solution Approach 1:
The patent merges multiple wavelength-generating functions into a single LED device, reducing the total component count and assembly requirements. This integration directly lowers manufacturing costs by eliminating the need for multiple separate LED packages and their associated mounting, wiring, and control circuitry.
3Device complexity
If phosphors are integrated with LEDs for white light production, then cost and complexity are reduced, but uniformity and reproducibility of light output become difficult to achieve
Solution Approach 1:
The patent segments the white light generation function into distinct wavelength-emitting active regions within the LED, each responsible for specific color wavelengths. This segmentation eliminates the need for phosphor conversion and associated uniformity problems, as each region independently generates its designated wavelength with precise spectral characteristics.
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 enables the production of uniform white light with reduced costs and complexity, improving the efficiency and reliability of LED-based lighting systems by integrating phosphors directly with LED dies before packaging, thus simplifying the lighting solution.
Implementation Method 1
A LED combined with one or more phosphors typically generates white light by combining the short-wavelength emission from the semiconductor LED with long-wavelength emission from the phosphor(s)
Implementation Method 2
Phosphors are typically composed of phosphorescent particles such as Y3Al5O12:Ce3+ (cerium-activated yttrium-aluminum-garnet, or YAG:Ce)
Data Source
AI summary
In accordance with certain embodiments, semiconductor dies are embedded within polymeric binder to form, e.g., freestanding white light-emitting dies and/or composite wafers containing multiple light-emitting dies embedded in a single volume of binder.