LED Resin Coating Adjustment for Wavelength Uniformity
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Solution Overview
Problem
The variation in light emission wavelengths of individual LED elements during the manufacturing process leads to inconsistent light emission characteristics in LED packages, resulting in defective products and yield loss due to uniform resin coating methods.
Innovation Solution
An LED package manufacturing system that includes a component mounting device, element characteristic information, resin coating information, and a resin coating device capable of adjusting resin quantities based on individual LED element measurements to achieve uniform light emission characteristics, using a light-passing member for test coating and excitation light to measure and correct resin application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If uniform resin coating quantity is applied to all LED elements, then the manufacturing process is simple and efficient, but the light emission characteristics of LED packages vary due to variations in individual LED element wavelengths
Solution Approach 1:
The patent applies local quality by adjusting the resin coating quantity according to the specific light emission characteristics of each LED element. The system measures the wavelength of each LED element and determines an appropriate resin coating quantity individually, rather than applying uniform coating to all elements. This localized adjustment ensures that each LED package achieves consistent light emission characteristics despite variations in individual LED elements.
Solution Approach 2:
The patent changes the parameter of resin coating quantity based on the measured light emission characteristics of each LED element. By establishing a relationship between LED wavelength and optimal resin coating quantity, the system dynamically adjusts the coating parameter to compensate for LED variations. This parameter change approach transforms the fixed uniform coating process into a variable process that adapts to each LED's specific characteristics.
2Manufacturing precision
If individual measurement and adjustment for each LED element is performed, then the light emission characteristics of LED packages are equalized, but the device complexity and measurement requirements increase
Solution Approach 1:
The patent implements feedback by measuring the light emission wavelength of each LED element and using this measurement information to determine the appropriate resin coating quantity. The system establishes a feedback loop where the measured LED characteristics inform the coating process, allowing real-time adjustment to achieve consistent LED package performance. This feedback mechanism enables the system to compensate for LED variations automatically.
Solution Approach 2:
The patent applies preliminary action by measuring the light emission characteristics of LED elements before the resin coating process. By obtaining wavelength measurement data in advance and pre-determining the appropriate resin coating quantity for each LED, the system prepares the necessary information before the actual coating operation. This preliminary measurement and planning step simplifies the subsequent coating process and ensures precision without requiring complex real-time adjustments during coating.
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 ensures uniform light emission characteristics of LED packages even with varying LED elements, enhancing production yield by accurately adjusting resin coating quantities based on measured light emission characteristics.
Implementation Method 1
a light source unit that is placed above the light-passing member carrying unit and emits excitation light for exciting the fluorescent substance
Data Source
AI summary
In resin coating, carrying a light-passing member test-coated with a resin on a light-passing member carrying unit; making a light source placed above the light-passing member carrying unit emit excitation light exciting the fluorescent substance; measuring light emission characteristics of the light by irradiating the excitation light emitted from the light source unit from above to the resin coated onto the light-passing member and receiving the light that the resin emits from below the light-passing member by a light emission characteristic measurement unit; obtaining a deviation between a measurement result of the light emission characteristic measurement unit and a prescribed light emission characteristic; and deriving the appropriate resin coating quantity of the resin to be coated onto the LED element as what is used for practical production based on the deviation.