Optical Conversion Material Caps Formed on Mold
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Solution Overview
Problem
Conventional methods for coating LEDs with phosphor result in significant waste due to low density of phosphor application, leading to inefficient use of optical conversion materials and unnecessary deposition on the LED package substrate.
Innovation Solution
A mold with high-density structures is used to form a unitary layer of optical conversion material, which is then removed as pre-formed caps that closely match the LED package substrate profile, reducing waste and ensuring precise application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional spray coating is used on LED package substrate, then phosphor can be applied to LEDs, but significant phosphor waste occurs due to low density application and unnecessary deposition on substrate
Solution Approach 1:
The patent applies preliminary action by pre-forming phosphor caps on a mold before transferring them to LEDs. The mold structures are prepared in advance with precise geometry, and phosphor is deposited only where needed on the mold, then the entire cap structure is transferred as a unit to the LED, eliminating waste from substrate deposition.
Solution Approach 2:
The patent introduces a mold as an intermediary object between the phosphor deposition process and the final LED application. The mold serves as a temporary carrier that enables precise phosphor placement, allowing the phosphor to be applied efficiently to the mold structures and then transferred to LEDs without direct substrate deposition waste.
2Manufacturing precision
If phosphor is sprayed on LED package substrate, then coverage can be achieved, but uniformity of light emission is compromised due to wasted phosphor and improper distribution
Solution Approach 1:
The mold structures are pre-formed with precise geometry that matches the desired cap shape, and phosphor is deposited on these pre-formed structures. This preliminary preparation ensures uniform phosphor distribution within the cap volume before transfer to LEDs, eliminating the distribution problems associated with direct substrate spraying.
Solution Approach 2:
The patent applies local quality by concentrating phosphor deposition precisely within the mold cavity structures where caps will be formed. The phosphor is applied only to the local regions needed for cap formation, with controlled density and distribution, rather than being sprayed broadly across the entire substrate surface.
3Ease of manufacture
If low density phosphor application is used, then application process is simple, but optical conversion material usage efficiency is poor
Solution Approach 1:
The patent merges the phosphor deposition process with the cap formation process. Instead of applying phosphor directly to LEDs or substrate, the phosphor is deposited onto pre-formed mold structures that will become the caps. This combining of processes allows efficient material usage while maintaining manufacturing simplicity through the unitary cap transfer approach.
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 minimizes phosphor waste and ensures accurate coverage of LEDs, improving the efficiency of optical conversion material usage and enhancing the uniformity of light emission.
Implementation Method 1
the phosphor material can absorb and 'downconvert' some of the blue light generated by the LED. That is, the phosphor material generates light, such as yellow light, in response to absorbing the blue light
Implementation Method 2
The unitary layer is irradiated with UV light to cure the backing material
Data Source
AI summary
A method of forming can be provided by applying an optical conversion material to a mold to form a unitary layer of optical conversion material and removing the unitary layer of optical conversion material from the mold.