LED Package Resin Coating Control for Wavelength Variation
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Solution Overview
Problem
The existing LED package manufacturing techniques suffer from variations in light emitting wavelengths of individual LED elements, leading to inconsistent light emitting characteristics and reduced production yield due to manufacturing process errors.
Innovation Solution
An LED package manufacturing system that includes a component mounting device, element characteristic information provision, resin coating device with measurement and correction capabilities, and a resin coating method to ensure consistent light emitting characteristics by adjusting the resin coating amount based on measured light emitting characteristics of each LED element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If LED elements are manufactured in bulk on a wafer, then production efficiency is improved, but light emitting wavelength variation increases
Solution Approach 1:
The patent applies preliminary action by measuring the light emitting characteristics of each LED element before mounting, and pre-establishing a map data that correlates mounting positions with individual element characteristics. This allows the resin coating amount to be predetermined for each position based on pre-measured data, rather than adjusting during the coating process itself.
Solution Approach 2:
The patent segments the coating control approach by treating each LED element individually rather than uniformly. The map data divides the substrate into discrete mounting positions, each with its own characteristic data, allowing customized resin coating amounts for each element based on its specific light emitting properties.
2Device complexity
If resin coating amount is kept uniform, then manufacturing complexity is reduced, but light emitting characteristic consistency deteriorates
Solution Approach 1:
The patent applies local quality by varying the resin coating amount according to the specific needs of each LED element's position on the substrate. Instead of uniform coating, the system dispenses different amounts of resin at different positions based on the pre-established map data, optimizing each local area's light emitting characteristics.
Solution Approach 2:
The patent implements feedback by using pre-measured light emitting characteristic data to inform and adjust the resin coating process. The map data serves as a feedback mechanism that guides the coating device to apply appropriate resin amounts to compensate for individual element variations.
3Manufacturing precision
If resin coating amount is increased to compensate for wavelength variation, then light emitting characteristic consistency is improved, but material waste increases
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the resin coating amount parameter based on the specific characteristics of each LED element. The system modifies the coating parameter (amount) for each position to achieve optimal light emitting characteristics without excessive material application.
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 system achieves consistent light emitting characteristics across LED packages, improving production yield by accurately adjusting resin coating amounts based on individual LED element characteristics.
Implementation Method 1
a light source unit (37) that emits an excitation light for stimulating the phosphor
Data Source
AI summary
In resin coating used for manufacturing the LED package in which the LED elements is covered with a resin containing a phosphor, a translucent member 43 coated with a resin 8 on trial as light emitting characteristic measurement is mounted on a translucent member mounting unit 41 having a light source unit, and an excitation light emitted from the light source unit is irradiated onto the resin 8 coated on the translucent member 43, and a deviation between a measurement result obtained by measuring the light emitting characteristics of a light emitted by the resin 8 by a light emitting characteristic measurement unit 39 and light emitting characteristics specified in advance is obtained, and an appropriate resin coating amount of the resin to be coated on the LED elements as real production is calculated on the basis of the deviation.