LED Phosphor Film Lamination for Uniform Dual-Color Output
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Solution Overview
Problem
Current methods for producing dual color LEDs are inefficient and result in low color quality due to the need for multiple steps and settling of phosphor particles in silicone solutions.
Innovation Solution
Controlling the rheology performance of colored phosphor compositions by adjusting the ratio of cure catalyst and silicone binder, or using a hydrosilylation curable organosiloxane composition, allows for one-step film lamination of LEDs with colored phosphor films, ensuring close rheology performance and uniform phosphor dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two different color LEDs are made separately and then assembled together, then color quality can be maintained, but production efficiency decreases due to multiple steps
Solution Approach 1:
The patent combines multiple LED chips and different colored phosphor films into a single integrated structure through one-step lamination. Multiple LED chips are positioned on a substrate, and multiple phosphor films with different colors are laminated onto the LED chips simultaneously in one processing step, eliminating the need for separate assembly steps for each color channel.
Solution Approach 2:
The patent prepares multiple phosphor films with controlled rheology properties in advance before lamination. The phosphor compositions are formulated with specific viscosity and flow characteristics that enable them to be laminated together in one step without mixing or settling during the process. This preliminary preparation of materials with compatible rheological properties allows the one-step lamination to succeed.
2Ease of manufacture
If phosphor particles are dispersed in silicone solutions, then colored phosphor films can be formed, but phosphor particles settle leading to low color quality
Solution Approach 1:
The patent changes the rheological parameters of the phosphor compositions, specifically controlling viscosity and flow properties. By adjusting these parameters, the phosphor particles remain suspended uniformly in the silicone binder without settling during the lamination and curing process. This parameter control ensures that the phosphor distribution remains homogeneous, maintaining color quality.
Solution Approach 2:
The patent uses composite phosphor compositions that combine phosphor particles with a silicone binder system having specific rheological properties. The composite material is designed so that the phosphor particles are evenly distributed and remain stable without settling. The composite formulation includes controlled catalyst-to-binder ratios that affect the curing behavior and particle suspension characteristics.
3Productivity
If different colored phosphor compositions are laminated in one step, then production efficiency increases, but rheology performance must be precisely controlled
Solution Approach 1:
The patent changes and controls the rheological parameters of different phosphor compositions to be compatible with each other. By adjusting viscosity, flow characteristics, and curing rates of different colored phosphor compositions, they can be laminated together in one step without one composition affecting the performance of another. This parameter matching simplifies the overall process despite handling multiple compositions.
Solution Approach 2:
The patent creates homogeneous rheological properties across different colored phosphor compositions. All phosphor compositions are formulated to have similar flow characteristics, viscosity ranges, and curing behaviors. This homogeneity allows them to be processed together in one lamination step as if they were a single material system, reducing the complexity of coordinating multiple different material behaviors.
4Manufacturing precision
If traditional two-step method is used with baffle and separate silicone solutions, then color separation is maintained, but production efficiency decreases and color quality suffers
Solution Approach 1:
The patent merges the functions of multiple separate processes into one lamination step. Instead of separately preparing and assembling different color channels with baffles, the patent laminates multiple phosphor films directly onto LED chips in one step. The controlled rheology of the phosphor compositions prevents mixing while enabling simultaneous processing, achieving both color separation and efficiency improvement.
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 production efficiency and color quality by achieving high uniformity in phosphor dispersion and faster curing times, resulting in improved dual color LEDs with better color consistency.
Implementation Method 1
using a hydrosilylation curable organosiloxane composition
Implementation Method 2
controlling rheology performance (e.g., maximum tan δ, minimum G′ and curing time) of the colored phosphor compositions
Data Source
AI summary
The present invention relates to method for producing LED by one step film lamination. The method comprises: laminating two or more LEDs with two or more colored phosphor films by one step film lamination; wherein each of the colored phosphor film comprises each other different colored phosphor composition which has a Maximum tan δ; and the difference of each Maximum tan δ varies within a range of 0-30%. In the present invention, the method for producing a LED may greatly improve production efficiency (i.e., dual and multi-color LEDs in one step) and lower cost of ownership. Further, it may improve uniformity of phosphor dispersion, thereby improve color quality of LEDs.