Light Converting Layer Uniform Distribution via Resin Bonding
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Solution Overview
Problem
Conventional methods for fabricating light converting layers with fluorescent material particles face challenges in achieving even distribution of particles, leading to color irregularities due to excessive use of glass powder or resin, which hinders uniform distribution of fluorescent material particles in both thickness and lateral directions.
Innovation Solution
A method involving the preparation of fluorescent material particles, forming a bonding layer made of resin on a base body, incorporating the particles into the layer, and hardening it to ensure uniform distribution, thereby forming a light converting layer with improved evenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass powder and fluorescent material particles are mixed with greater amount of glass powder, then adhesion between particles is improved, but distribution uniformity of fluorescent material particles deteriorates
Solution Approach 1:
The patent changes the material parameter from glass powder to resin, which fundamentally alters the binding mechanism. Resin provides adhesion through chemical bonding and wetting properties without requiring excessive amounts, thereby maintaining both adhesion strength and distribution uniformity of fluorescent particles.
Solution Approach 2:
The patent creates a composite material system where resin and fluorescent particles are combined in optimized proportions. This composite approach allows the resin to serve as an effective binder at lower concentrations compared to glass powder, resolving the contradiction between adhesion and uniform distribution.
2Ease of manufacture
If greater amount of resin is used to maintain appropriate flowability, then processability is improved, but distribution uniformity of fluorescent material particles deteriorates
Solution Approach 1:
The patent optimizes the resin-to-fluorescent particle ratio parameter, using resin in controlled, moderate amounts rather than excess. This parameter optimization maintains sufficient flowability for processing while preventing resin from dominating the mixture and causing poor particle distribution.
Solution Approach 2:
The patent references and improves upon conventional resin-based methods by carefully controlling resin content. It learns from the conventional approach's flowability benefits while correcting its drawback of poor distribution control through optimized resin usage.
3Strength
If smaller amount of fluorescent material particles is used compared to binder, then adhesion is improved, but distribution uniformity deteriorates
Solution Approach 1:
The patent fundamentally changes the binder material from glass powder or excess resin to optimized resin, which provides superior adhesion per unit volume. This allows fluorescent particles to be used in higher concentrations while maintaining both adhesion and uniform distribution, reversing the conventional trade-off.
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 a light emitting device with reduced color unevenness by ensuring uniform distribution of fluorescent material particles, enhancing light emitting efficiency and reducing waste by reusing excess particles.
Implementation Method 1
forming a bonding layer made of a resin on a base body; incorporating the fluorescent material particles in the bonding layer, and hardening the bonding layer
Data Source
AI summary
Provided Is a method of forming a light converting layer capable of uniformly distributing fluorescent material particles, a method of manufacturing a light converting member capable of distributing fluorescent material particles, and a method of manufacturing a light emitting device capable of controlling color irregularities. The method of forming a light converting member comprising steps of, preparing fluorescent material particles, forming a bonding layer made of a resin on a base body; incorporating the fluorescent material particles in the bonding layer; and hardening the bonding layer.