LED Wavelength Transforming Layer for Uniform Dominant Wavelength
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Solution Overview
Problem
The non-uniform distribution of dominant wavelengths in light-emitting diode (LED) chips affects the consistency of their characteristics and the quality of products, particularly in applications requiring tight wavelength distribution, leading to inefficient usage and increased manufacturing costs due to time-consuming sorting and binning processes.
Innovation Solution
A wavelength transforming layer, composed of fluorescent or phosphor materials, is formed on the light-emitting stacked layers to converge and convert the dominant wavelengths, reducing the variation and eliminating the need for sorting and binning processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional LED manufacturing process is used, then production efficiency is maintained, but dominant wavelength distribution becomes non-uniform affecting product consistency
Solution Approach 1:
The patent applies preliminary action by incorporating a wavelength transforming layer during the LED wafer manufacturing process itself, rather than performing wavelength sorting after chip fabrication. This preliminary wavelength convergence step ensures uniform dominant wavelength distribution across all chips before they are diced and packaged, eliminating the need for subsequent sorting operations and maintaining high production efficiency.
Solution Approach 2:
The patent utilizes parameter changes by modifying the optical properties of the LED wafer through the wavelength transforming layer. This layer transforms the dominant wavelength of emitted light from a wide distribution (e.g., 450-470 nm) to a narrow distribution centered at a specific wavelength, thereby improving wavelength uniformity without compromising productivity.
2Manufacturing precision
If sorting and binning processes are implemented, then product consistency is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent eliminates time-consuming sorting and binning processes by performing wavelength convergence as a preliminary action during wafer fabrication. The wavelength transforming layer is applied to the entire LED wafer before dicing, ensuring all resulting chips have uniform wavelength characteristics without requiring post-fabrication sorting operations.
Solution Approach 2:
The patent merges the wavelength transformation function into the LED wafer structure itself by integrating the wavelength transforming layer with the light-emitting stacked layers. This combination eliminates the need for separate sorting and binning processes, as the wavelength uniformity is built-in rather than achieved through subsequent separation operations.
3Adaptability or versatility
If wavelength sorting is performed, then available chips for tight wavelength applications increase, but manufacturing complexity increases
Solution Approach 1:
The patent merges the wavelength control function directly into the LED wafer structure through the wavelength transforming layer, eliminating the need for complex post-fabrication sorting and binning processes. This integration provides uniform wavelength characteristics across all chips, increasing adaptability for wavelength-sensitive applications while simplifying the overall manufacturing process.
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 achieves a more uniform dominant wavelength distribution, enhancing the efficiency of LED usage and reducing manufacturing costs by eliminating the need for sorting and binning, while ensuring consistent color temperature in white light generation.
Implementation Method 1
a wavelength transforming layer formed on the plurality of light-emitting stacked layers to converge and convert the dominant wavelengths emitted from the light-emitting stacked layers
Implementation Method 2
A wavelength transforming layer, composed of fluorescent or phosphor materials, is formed on the light-emitting stacked layers to converge and convert the dominant wavelengths
Data Source
AI summary
This application discloses a light-emitting device with narrow dominant wavelength distribution and a method of making the same. The light-emitting device with narrow dominant wavelength distribution at least includes a substrate, a plurality of light-emitting stacked layers on the substrate, and a plurality of wavelength transforming layers on the light-emitting stacked layers, wherein the light-emitting stacked layer emits a first light with a first dominant wavelength variation; the wavelength transforming layer absorbs the first light and converts the first light into the second light with a second dominant wavelength variation; and the first dominant wavelength variation is larger than the second dominant wavelength variation.