Light Emitting Device Hue Uniformity via Segmented Resin
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Solution Overview
Problem
Densely mounted light-emitting devices with phosphor in the resin experience hue deviations due to varying light travel distances through the phosphor layer, making it difficult to achieve uniform chromaticity in the emitted light.
Innovation Solution
A light-emitting device design featuring a board with densely mounted light-emitting elements, where a phosphor-free first resin fills the spaces between elements and a phosphor-containing second resin covers the exposed areas, ensuring consistent light travel distance and hue accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If multiple light-emitting elements are mounted densely to reduce emission region size, then light condensation property is improved, but hue uniformity deteriorates due to varying light travel distances through the phosphor layer
Solution Approach 1:
The patent divides the sealing resin into two distinct parts: a first sealing resin containing phosphor that covers the light-emitting elements, and a second sealing resin free from phosphor that fills the spaces between elements. This segmentation allows different regions to have different optical properties, solving the hue uniformity problem while maintaining dense mounting configuration.
Solution Approach 2:
The patent applies different material compositions to different spatial locations: phosphor is placed only in regions where light emission occurs (covering the elements), while phosphor-free resin is placed in inter-element spaces. This local differentiation ensures that light traveling through adjacent elements experiences consistent phosphor interaction, achieving uniform hue across the emission region.
2Use of energy by moving object
If phosphor is dispersed uniformly in the resin to achieve desired chromaticity, then light emission efficiency is improved, but hue deviation occurs due to varying traveling distances of light in the phosphor layer
Solution Approach 1:
The patent segments the phosphor distribution into two zones: a phosphor-containing first sealing resin that provides efficient light conversion, and a phosphor-free second sealing resin that eliminates unwanted light scattering. This segmentation maintains high emission efficiency while ensuring consistent chromaticity by controlling exactly where phosphor interacts with light.
Solution Approach 2:
The phosphor-free second sealing resin acts as an intermediary medium between light-emitting elements, providing a clear optical path that prevents additional phosphor-induced hue variations. This intermediary ensures that light from adjacent elements travels through consistent media, achieving uniform chromaticity while maintaining overall emission efficiency.
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 configuration reduces hue deviations, allowing for uniform chromaticity in the emitted light by maintaining consistent light travel through the phosphor layer, regardless of the emission position or direction from the light-emitting elements.
Implementation Method 1
LED elements emitting light such as blue light are sealed with a resin containing a phosphor, which is excited by the light from the LED elements to yield light to be mixed therewith to provide light such as white light
Data Source
AI summary
A light-emitting device and a manufacturing method thereof are provided, which device yields light exhibiting an actual hue with a deviation reduced as much as possible from a designed hue value, the light being a mixture of light emitted from a plurality of light-emitting elements mounted densely and excited light from a phosphor contained in a resin sealing the light-emitting elements. The light-emitting device includes a board, a plurality of light-emitting elements mounted densely on the board, a first resin free from any phosphor, placed among the plurality of light-emitting elements, and a second resin containing a phosphor and covering an exposed part of the plurality of light-emitting elements.