Wavelength-Conversion Binder for LED Color Uniformity
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Solution Overview
Problem
The high cost and complexity of LED-based lighting systems, particularly in broad-area general lighting applications, due to the need for precise control of multiple LEDs and the use of phosphors for white light production, which can result in non-uniform light distribution and increased bulk and efficiency losses.
Innovation Solution
A method involving semiconductor dies positioned within a frame and coated with a binder to form a composite frame wafer, where the binder contains wavelength-conversion materials like phosphors, allowing for uniform and efficient integration of light-emitting elements with improved color uniformity and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple LEDs operating at different wavelengths are used to generate white light, then the desired light intensity and color can be achieved, but the system complexity and cost increase due to the need for precise control of multiple LEDs
Solution Approach 1:
The patent combines multiple wavelength-conversion materials (different phosphors or quantum dots) into a single integrated layer that converts blue LED light into multiple wavelengths simultaneously. This merging approach eliminates the need for separate LED chips and their associated control systems, reducing device complexity while maintaining the ability to produce white light with desired intensity and color characteristics.
Solution Approach 2:
The patent introduces wavelength-conversion materials as intermediary substances between the blue LED light source and the final white light output. These materials act as mediators that transform the single-wavelength blue light into multi-wavelength white light, eliminating the need for direct control of multiple LEDs while achieving the same optical effect.
2Illumination intensity
If phosphors are used for light conversion in LED-based systems, then white light can be produced, but the light distribution becomes non-uniform and efficiency is reduced
Solution Approach 1:
The patent changes the physical and chemical parameters of the wavelength-conversion materials, including using quantum dots with size-tunable emission wavelengths, optimizing phosphor particle sizes and distributions, and adjusting refractive indices of binder materials. These parameter changes improve light extraction efficiency, reduce internal reflections, and minimize energy loss while maintaining uniform white light output.
Solution Approach 2:
The patent employs composite material structures combining multiple phosphors or quantum dots with optimized binder materials. These composite structures enable simultaneous wavelength conversion across the visible spectrum while maintaining high efficiency and uniform light distribution, overcoming the limitations of single-material phosphor systems.
3Illumination intensity
If phosphors are integrated with LED chips, then white light can be generated, but the integration process is difficult with poor uniformity and reproducibility
Solution Approach 1:
The patent applies wavelength-conversion materials to the LED chip surface before the chip is fully packaged or mounted. This preliminary integration step allows for more precise control of material distribution and thickness uniformity, improving manufacturing precision and reproducibility while enabling subsequent white light generation with consistent characteristics.
Solution Approach 2:
The patent implements spatially varying distributions of wavelength-conversion materials, such as gradient phosphor concentrations or zone-specific quantum dot placements. This local quality approach enables optimization of light conversion in different regions of the LED chip, improving overall uniformity and addressing manufacturing variability through localized material property adjustments.
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 enables the production of white light with consistent color temperature and reduced divergence, achieving high efficiency and low costs by integrating phosphors directly with light-emitting elements before mounting on a circuit board, eliminating the need for complex control systems and additional light-mixing components.
Implementation Method 1
The binder may contain a wavelength-conversion material such as a phosphor or a collection of quantum dots
Implementation Method 2
unconverted light and converted light emitted by the semiconductor die combining to form mixed light
Data Source
AI summary
In accordance with certain embodiments, electronic devices feature a polymeric binder, a frame defining an aperture therethrough, and a semiconductor die (e.g., light-emitting or a light-detecting element) suspended in the binder and within the aperture of the frame.