LED Mixed-Light Binning for Wide Color Temperature Tuning
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Solution Overview
Problem
The existing methods for manufacturing light emitting devices with color tuning capabilities face a decrease in yield due to binning challenges when multiple light sources with different color temperatures are used, particularly when trying to achieve a wide range of color temperatures between 2000K and 5000K.
Innovation Solution
A method involving a light emitting device with a package containing a first and a second light source, each with a wavelength conversion member, where light from both sources is mixed and binned based on the chromaticity of the mixed light to improve yield and color tuning capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If binning is performed separately for each light source with different color temperatures, then the chromaticity of each light source can be controlled, but the yield of light emitting devices decreases
Solution Approach 1:
The patent merges the binning process for multiple light sources into a single simultaneous binning operation. Instead of performing separate binning for each light source with different color temperatures, the invention evaluates the combined chromaticity of all light sources together and performs one binning decision, thereby maintaining chromaticity control while improving yield.
2Adaptability or versatility
If multiple light sources with different color temperatures are used for color tuning, then the color temperature range can be expanded, but the binning complexity increases
Solution Approach 1:
The patent creates a universal binning method that handles multiple light sources with different color temperatures through a single chromaticity evaluation process. This multi-functional approach allows the same binning procedure to work for any combination of light sources, simplifying the overall process while maintaining the ability to achieve a wide color temperature range.
3Reliability
If separate binning is performed for each color temperature light source, then individual light source quality can be ensured, but manufacturing efficiency decreases
Solution Approach 1:
The patent combines multiple quality evaluation steps into a single binning operation that assesses the overall chromaticity of the light emitting device. This merging maintains quality assurance by evaluating the final combined light output while significantly improving manufacturing efficiency by reducing the number of separate binning operations required.
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 enhances the yield of light emitting devices capable of color tuning by allowing for precise binning of mixed light, thereby reducing variations and improving the manufacturing efficiency across a broader range of color temperatures.
Implementation Method 1
a first light source placed within the recess, and including a first light emitting element and a first wavelength conversion member; a second light source placed within the recess
Implementation Method 2
including a first light emitting element and a first wavelength conversion member; and a second light emitting element and a second wavelength conversion member
Data Source
AI summary
A method for manufacturing a light emitting device includes preparing a light emitting device including: a package defining a recess; a first light source placed within the recess, and including a first light emitting element and a first wavelength conversion member; a second light source placed within the recess; and a second wavelength conversion member in contact with and covering the first light source and the second light source, the first light source and the second light source being configured to emit light independently of each other. The method further includes: emitting light simultaneously from the first light source and the second light source to obtain mixed light for which light from the first light source, light from the second light source, and light from the second wavelength conversion member are mixed; determining a chromaticity of the mixed light; and binning the mixed light based on the chromaticity.