LED Wavelength Conversion Coating with Real-Time CCT Feedback Control
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Solution Overview
Problem
Fabricating light emitting diode (LED) dice with consistent color balance is challenging due to variations in the fabrication process affecting the wavelength conversion layers, leading to undesirable color rendition and balance in white light output.
Innovation Solution
A method and system for continuously evaluating and adjusting the correlated color temperature (CCT) of the output electromagnetic radiation by controlling the coating of a wavelength conversion material on a transparent substrate, ensuring the desired color temperature and spectral distribution are achieved, using a monitoring system and control system in conjunction with a coating system to deposit the wavelength conversion material in viscous form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fabrication processes are used to deposit wavelength conversion layers, then manufacturing simplicity is maintained, but color balance consistency deteriorates due to process variations
Solution Approach 1:
The patent implements real-time feedback control by continuously monitoring the correlated color temperature (CCT) of the wavelength conversion layer during fabrication and adjusting deposition parameters accordingly. This closed-loop system measures the actual color output and modifies the deposition process to maintain target color specifications, directly resolving the contradiction between manufacturing precision and process complexity.
Solution Approach 2:
The patent dynamically adjusts deposition parameters such as material flow rate, substrate temperature, and deposition speed based on real-time CCT measurements. By changing these process parameters in response to measured color characteristics, the system maintains consistent color balance despite variations in material properties or environmental conditions.
2Manufacturing precision
If real-time monitoring and adjustment systems are implemented, then color balance consistency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The fabrication system performs self-correction by automatically adjusting deposition parameters based on real-time color measurements without requiring external intervention. The system monitors its own output and modifies its operation to maintain specifications, reducing the need for complex manual control systems and specialized manufacturing infrastructure.
Solution Approach 2:
By implementing automated feedback control, the system replaces complex manual monitoring and adjustment procedures with an automated closed-loop control mechanism. This reduces the skill level required for operators and simplifies the overall manufacturing process while maintaining high color consistency.
3Manufacturing precision
If wavelength conversion material composition is varied to achieve desired color temperature, then color characteristics are improved, but manufacturing precision control becomes more difficult
Solution Approach 1:
The patent controls color temperature by dynamically adjusting deposition parameters (flow rate, temperature, speed) rather than changing material composition. This approach maintains manufacturing precision by controlling physical process parameters that are easier to regulate accurately than chemical composition, while still achieving the desired color characteristics through controlled thickness and density variations.
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
Enables the production of light emitting diode (LED) dice with controlled color characteristics, achieving consistent color balance and spectral distribution, thereby ensuring reliable white light output with desired color temperature.
Implementation Method 1
a wavelength conversion material in viscous form configured to convert input electromagnetic radiation in a first spectral region to output electromagnetic radiation in a second spectral region
Data Source
AI summary
A method for fabricating light emitting diode (LED) dice includes the steps of coating a transparent substrate with a wavelength conversion material, continuously evaluating a correlated color temperature (CCT) of the output electromagnetic radiation produced by the wavelength conversion material and comparing the correlated color temperature (CCT) to a target correlated color temperature (CCT), and controlling the coating step responsive to feedback from the evaluating and comparing step to adjust the correlated color temperature (CCT) to achieve the target correlated color temperature (CCT). A system for fabricating light emitting diode (LED) dice includes a coating system, a monitoring system, and a control system configured to control the coating system to adjust the correlated color temperature (CCT) of the wavelength conversion material on the transparent substrate to achieve the target correlated color temperature (CCT).