Multi-Resin LED Package Module for Luminous Efficiency

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Solution Overview

Problem

LED package modules using UV LEDs experience reduced luminous efficiency due to yellowing of plastics over time, which is not effectively addressed by existing heat-dissipating and mechanical designs.

Innovation Solution

An LED package module design featuring a substrate with LED chips, a red resin portion with red phosphor, a green resin portion with green phosphor, and a blue resin portion with blue phosphor, where the red and green resin portions are molded around individual LED chips and the blue resin portion encompasses both, enhancing luminous efficiency and reducing size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If UV LEDs are used in LED package modules, then lighting applications can be expanded, but luminous efficiency decreases due to yellowing of plastics

Engineering Contradiction:
Improvelighting applicationsVSAvoidluminous efficiency
Core Design Contradiction:
Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent extracts the harmful plastic material from the LED package module design. Instead of using plastic lenses and housings that yellow under UV exposure, the invention uses bare LED chips mounted on a substrate with metal heat dissipation structures, eliminating the material that causes luminous efficiency degradation while maintaining versatility in lighting applications

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs composite material structures combining metal substrates with heat dissipation fins and ceramic or metal encapsulants. This composite approach replaces单一 plastic materials with a multi-material system that resists UV degradation, maintaining both functional versatility and high luminous efficiency over time

Inventive Principle:
Principle #40Composite materials

2Reliability

If mechanical design and heat-dissipating design are optimized, then reliability improves, but device complexity increases

Engineering Contradiction:
Improvereliability of light source devicesVSAvoidmechanical design complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the heat dissipation function directly into the substrate structure itself. The metal substrate integrates thermal conduction pathways and fin structures as an inherent part of the mounting platform, rather than adding separate heat sinks and thermal management components. This consolidation improves reliability through effective heat management while reducing overall device complexity

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The metal substrate serves multiple functions simultaneously: it provides mechanical support for mounting LED chips, conducts heat away from the light-emitting elements, and acts as an electrical connection platform. This multi-functionality approach improves reliability through robust thermal and mechanical performance while avoiding the need for multiple separate components that would increase complexity

Inventive Principle:
Principle #6Universality (Multi-functionality)

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

The design prevents luminous efficiency reduction by effectively mixing red and green light to produce high-quality white light, improving luminance while minimizing module size and weight.

Implementation Method 1

a first color resin portion molded around at least one of the plurality of LED chips; a second color resin portion molded around all of the LED chips except for the LED chip around which the first color resin portion is molded, and having a different color from the first color resin portion

Methodology Applied
Scientific EffectPhosphorescence: Phosphorescence

Data Source

PatentUS8278671B2Led package module
Publication Date: 2012.10.02 SAMSUNG ELECTRONICS CO LTD
  • US8278671B2 patent drawing
  • US8278671B2 patent drawing
  • US8278671B2 patent drawing

AI summary

An LED package module according to an aspect of the invention may include: a substrate having predetermined electrodes thereon; a plurality of LED chips mounted onto the substrate, separated from each other at predetermined intervals, and electrically connected to the electrodes; a first color resin portion molded around at least one of the plurality of LED chips; a second color resin portion molded around all of the LED chips except for the LED chip around which the first color resin portion is molded, and having a different color from the first color resin portion; and a third color resin portion encompassing both the first color resin portion and the second color resin portion and having a different color from the first color resin portion and the second color resin portion.