Resin Coating Device for LED Light Emission Control
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Solution Overview
Problem
The existing LED package manufacturing techniques suffer from variations in light emission wavelength of individual LED elements, leading to inconsistent light emission characteristics in the final product, which reduces production yield due to error factors in the manufacturing process.
Innovation Solution
A resin coating device and method that includes a resin coating unit with variable discharge, a coating control unit for measurement and production coating, a light source for excitation, a translucent member for light emission characteristic measurement, and a derivation unit to adjust the resin coating amount based on measured characteristics, ensuring consistent light emission across LED packages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the height of the resin package portion is equalized by pouring excessive resin, then the resin package portion having a given amount of resin with a specified height is formed, but the variation in the light emission wavelength of the singulated LED elements is reflected on the variation in the light emission characteristic of the LED package
Solution Approach 1:
The invention changes the parameter of resin coating amount from a fixed value to a variable value that is adjusted based on the light emission wavelength of each LED element. The resin coating amount is determined according to the measured light emission characteristics, allowing compensation for wavelength variations while maintaining consistent light emission in the finished product.
Solution Approach 2:
The invention implements a feedback mechanism where the light emission wavelength of each LED element is measured first, and then the resin coating amount is adjusted based on this measurement. The measured light emission characteristics serve as feedback to control the subsequent resin coating process, ensuring that variations in LED element characteristics are compensated for in the final product.
2Ease of manufacture
If a fixed resin coating amount is used for all LED elements, then the manufacturing process is simple, but the light emission characteristic variation due to LED element differences cannot be corrected
Solution Approach 1:
The invention makes the resin coating amount dynamic rather than fixed. The coating amount is adjusted in real-time based on the measured light emission characteristics of each LED element, allowing the manufacturing process to adapt to individual element variations while maintaining overall process efficiency.
Solution Approach 2:
The invention changes the resin coating parameter from a constant value to a variable value that depends on the LED element's light emission characteristics. This parameter adjustment enables compensation for element variations without significantly complicating the manufacturing process.
3Reliability
If the resin coating amount is increased to compensate for wavelength variation, then the light emission characteristic can be equalized, but the amount of resin consumption increases
Solution Approach 1:
The invention applies local quality by providing different resin coating amounts to different LED elements based on their specific light emission characteristics. Each element receives a customized coating amount tailored to its individual needs, rather than applying a uniform coating that would waste resin on elements that don't require additional coating.
Solution Approach 2:
The invention optimizes resin consumption by dynamically adjusting the coating parameter based on actual LED element characteristics. This ensures that resin is applied only where needed to achieve the desired light emission characteristics, minimizing waste while maintaining product quality.
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 solution enables equalization of light emission characteristics across LED packages, improving production yield by accurately adjusting resin coating amounts based on individual LED element variations, and facilitates easy disposal and movement of translucent members within the coating device.
Implementation Method 1
a light source unit that emits an excitation light that excites the phosphor
Data Source
AI summary
A translucent member 41 that has been trial-coated with a resin 8 for measurement of a light emission characteristic is placed on a translucent member placement portion 53, an excitation light that excites a phosphor is emitted from a light source unit 42 disposed above, the resin 8 coated on the translucent member 41 is irradiated with the excitation light from above, a deviation between a measurement result obtained by measuring the light emission characteristic of the light emitted from the resin 8, and a light emission characteristic specified in advance is obtained, and an appropriate resin coating amount of the resin to be coated on the LED element for actual production is derived on the basis of the deviation.