Resin Discharge Feedback Control for LED Chromaticity
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Solution Overview
Problem
The viscosity of liquid resin in light-emitting device manufacturing increases over time, leading to inconsistent discharge quantities and chromaticity fluctuations in the final product, which is difficult to prevent completely, hindering mass production.
Innovation Solution
A method involving substrates with packages having recesses for potting, where a resin member with fluorescent particles is supplied, and the quantity adjusted based on measured height to maintain consistent discharge, using feedback to adjust the resin supply and reduce viscosity fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid resin is stored in syringe for mass production, then productivity is improved, but viscosity increases over time causing discharge quantity to fluctuate
Solution Approach 1:
The patent implements a feedback mechanism where the discharge quantity of liquid resin is continuously monitored, and when deviations occur due to viscosity changes, the system automatically adjusts the discharge parameters to maintain consistent discharge quantity, enabling both mass production and precision control
Solution Approach 2:
The patent transforms the static discharge process into a dynamic controlled process by continuously monitoring viscosity changes and adjusting discharge parameters in real-time, allowing the system to adapt to changing resin properties while maintaining production efficiency
2Manufacturing precision
If liquid resin is used quickly to prevent viscosity increase, then discharge quantity consistency is improved, but mass production is hindered
Solution Approach 1:
The feedback control system allows resin to be stored in syringes for extended periods while automatically compensating for viscosity changes, eliminating the need for quick usage and enabling both precision and mass production
3Reliability
If discharge quantity changes due to viscosity increase, then chromaticity of light-emitting device changes, but this is difficult to prevent completely
Solution Approach 1:
The feedback mechanism monitors discharge quantity and correlates it with chromaticity outcomes, automatically adjusting subsequent discharges to maintain both quantity consistency and chromaticity stability without requiring complex manual intervention
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 reduces chromaticity fluctuations by ensuring consistent resin discharge, enabling efficient mass production of light-emitting devices with stable color characteristics.
Implementation Method 1
a resin member containing particles of a fluorescent material is supplied into the recess of each of the packages of the first substrate
Data Source
AI summary
A method for manufacturing a light-emitting device includes: providing first and second substrates each including a plurality of packages, the packages each having a recess and a light-emitting element mounted in the recess; performing potting by supplying a resin member containing particles of a fluorescent material into the recess of each of the packages of the first substrate; spreading the resin member in the recess of each of the packages of the first substrate; measuring a height of an upper surface of the resin member spread in the recess of at least one of the packages of the first substrate; and adjusting a quantity of the resin member to be supplied into the recess of each of the packages of the second substrate depending on the measured height of the upper surface of the resin member.