LED Module with Dual Viscosity Phosphor Layers
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Solution Overview
Problem
The existing LED modules with concentrically arranged light-emitting areas face challenges in downsizing the mounting substrate due to increased substrate size caused by the arrangement of dam materials, which complicates the wiring system and manufacturing process.
Innovation Solution
The LED module design features a first LED group with a rod-like light-emitting area and a second LED group outside it, surrounded by a dam material, with different fluorescent resins having varying viscosities and shapes to optimize light emission and substrate size, including a current limiting circuit for controlled light emission states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If concentric light-emitting areas are arranged on the mounting substrate, then color mixing properties are improved, but the substrate size increases
Solution Approach 1:
The patent places the first light-emitting area (circular) inside the second light-emitting area (ring-shaped), creating a nested concentric arrangement that maximizes color mixing within a compact footprint. The inner circular area and outer ring area work together to produce mixed-color light without requiring excessive substrate area.
Solution Approach 2:
The patent utilizes vertical layering by stacking phosphor layers (first phosphor layer 831, second phosphor layer 832) above the LED chips, creating a three-dimensional light conversion structure. This vertical dimension allows efficient color mixing without expanding the horizontal substrate area.
2Illumination intensity
If dam materials are arranged concentrically to separate light-emitting areas, then light emission control is improved, but the wiring system and manufacturing process become complicated
Solution Approach 1:
The patent extracts the light emission control function from the dam material structure and transfers it to the LED chip arrangement and phosphor layer configuration. By using LED groups with different color temperatures and strategically placing phosphor layers, the patent achieves independent control of light emission from different areas without requiring complex dam material wiring systems.
Solution Approach 2:
The mounting substrate serves multiple functions: it mechanically supports the LED chips, provides electrical connections through wiring patterns, and facilitates heat dissipation. The phosphor layers simultaneously perform light conversion and structural sealing functions, reducing the need for separate dam materials and simplifying the overall structure.
3Shape
If dam materials are used to surround light-emitting areas, then light emission boundaries are defined, but the manufacturing process becomes complicated
Solution Approach 1:
The patent merges the boundary definition function with the phosphor layer structure itself. The phosphor layers are applied directly over the LED chips in specific patterns (circular first phosphor layer, ring-shaped second phosphor layer), and these layers naturally define the light-emitting area boundaries through their geometric shapes, eliminating the need for separate dam material structures.
Solution Approach 2:
The patent applies different phosphor materials with specific properties to different locations: the first phosphor layer (emitting yellow light) is applied to the inner circular area, while the second phosphor layer (emitting orange light) is applied to the outer ring area. This local differentiation of material properties creates distinct light emission zones with clear boundaries without requiring physical barriers.
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 design allows for a downsized mounting substrate while maintaining high color mixing properties and simplifying the manufacturing process by eliminating the need for a dam material between light-emitting areas, preventing 'waviness' in the fluorescent resin and improving optical design ease.
Implementation Method 1
a first fluorescent resin coating the first LED group and causing the first light-emitting area to emit light having a first color temperature
Implementation Method 2
a second fluorescent resin coating at least the second LED group and causing the second light-emitting area to emit light having a second color temperature higher than the first color temperature
Data Source
AI summary
An LED module according to the present invention includes: a mounting substrate; a first LED group including a plurality of LEDs mounted in a first light-emitting area extending in a first direction on the mounting substrate; a second LED group including a plurality of LEDs mounted in a second light-emitting area located outside the first light-emitting area; a dam material surrounding a periphery of the second light-emitting area; a first fluorescent resin coating the first LED group and causing the first light-emitting area to emit light having a first color temperature; and a second fluorescent resin coating at least the second LED group and causing the second light-emitting area to emit light having a second color temperature higher than the first color temperature, and viscosity of the first fluorescent resin is higher than viscosity of the second fluorescent resin.