LED Fluorescent Solution Dispensing Feedback Control
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Solution Overview
Problem
Existing methods for manufacturing LED devices struggle to finely adjust the amount of fluorescent solution dispensed onto LED chips due to limitations in measuring small weights and changes in viscosity and LED chip characteristics, leading to difficulties in maintaining predetermined light color coordinates.
Innovation Solution
A method and apparatus that involve dispensing a fluorescent solution onto LED chips, measuring light characteristics, calculating a representative value, and adjusting the dispensing amount using a feedback loop to ensure accurate color coordinate values, with the option of additional dispensing by a secondary dispenser to achieve target values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If general dispensers are used to dispense fluorescent solution, then the manufacturing process is simple, but the dispensing amount cannot be finely adjusted due to scale measurement limitations (minimum 1-10g)
Solution Approach 1:
The patent replaces the mechanical scale-based measurement system with an optical measurement system. A spectroscope measures light characteristics (color coordinates) of the LED chip after fluorescent solution dispensing, and this optical information is used to calculate and control the dispensing amount, achieving fine adjustment precision beyond mechanical scale limitations.
Solution Approach 2:
The patent implements a feedback control system where the spectroscope measures the light characteristics of the LED chip after fluorescent solution dispensing, the controller calculates the actual dispensing amount based on color coordinate changes, and adjusts the dispenser for subsequent operations. This closed-loop feedback enables precise control of dispensing amounts.
2Reliability
If the fluorescent solution viscosity changes due to temperature or aging, then the solution remains usable, but the dispensing amount becomes difficult to control accurately
Solution Approach 1:
The patent enables the system to automatically adapt to viscosity changes through self-measurement and self-adjustment. The spectroscope continuously measures the light characteristics, and the controller automatically calculates and adjusts the dispensing parameters based on the measured color coordinate changes, without requiring manual viscosity measurement or calibration.
Solution Approach 2:
The patent dynamically adjusts dispensing parameters (amount, speed, pressure) based on measured light characteristic changes. When viscosity changes cause color coordinate deviations, the controller modifies the dispensing parameters to compensate, maintaining accurate color control despite solution property variations.
3Manufacturing precision
If LED chip characteristics vary due to previous manufacturing conditions, then production flexibility is maintained, but consistent light characteristics become difficult to achieve
Solution Approach 1:
The patent uses feedback control to measure the actual light characteristics of each LED chip (or sample chips) and adjusts the fluorescent solution dispensing amount accordingly. This ensures that despite variations in LED chip characteristics from different manufacturing batches, the final LED device achieves consistent color coordinates.
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 allows for precise adjustment of light characteristics, improving the quality of LED devices by ensuring color coordinate values fall within predetermined ranges, even with changes in viscosity and LED chip characteristics, thereby enhancing the manufacturing process efficiency and product consistency.
Implementation Method 1
When each LED chip is coated with a fluorescent solution including a fluorescent material, color of light generated from an LED device is changed according to the amount of fluorescent material coated.
Data Source
AI summary
An apparatus and method of manufacturing a light emitting diode (LED) device, and more particularly, an apparatus and method of manufacturing an LED device by dispensing a fluorescent solution prepared by mixing a fluorescent material with a liquid synthetic resin, onto an LED chip. An apparatus and method of manufacturing an LED device, whereby an appropriate amount of fluorescent solution simultaneously in consideration of several factors, such as characteristics of an LED chip and viscosity of the fluorescent solution may be dispensed onto the LED chip, is provided. An apparatus and method of manufacturing an LED device, whereby an appropriate amount of fluorescent solution may be calculated actively in consideration of viscosity of the fluorescent solution, a change in characteristics of an LED chip, or the like, and the appropriate amount of fluorescent solution may be dispensed onto the LED chip, is provided.