Optical Encapsulant Volume Control for LED Devices
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Solution Overview
Problem
The existing methods for dispensing encapsulant material into semiconductor light emitting devices struggle to consistently provide the correct volume, leading to inadequate or excessive cushioning for the lens, which affects the device's performance and yield due to variations in the dispensing apparatus and reflector cavity volume.
Innovation Solution
A method and apparatus that use reflected optical radiation to detect and control the volume of encapsulant material, ensuring the surface conforms to a predetermined shape, thereby providing the appropriate cushioning by dispensing the correct amount of encapsulant into the reflector cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dispensing methods are used to dispense encapsulant material, then the dispensing process is simple, but the volume precision and cushioning consistency deteriorate due to variations in dispensing apparatus and reflector cavity volume
Solution Approach 1:
The patent implements an optical feedback system where a light source illuminates the encapsulant surface and a sensor detects the reflected light pattern. The detected optical indicia provides real-time feedback about the encapsulant volume, allowing the system to adjust dispensing to achieve the target volume with high precision despite variations in the dispensing apparatus or cavity geometry.
Solution Approach 2:
The patent replaces traditional mechanical volume measurement and control methods with an optical detection system. Instead of relying on mechanical dispensing precision alone, the system uses optical radiation reflection patterns to non-contactly detect and control the encapsulant volume, achieving higher precision without increasing mechanical complexity.
2Measurement precision
If optical radiation detection is implemented to control dispensing volume, then the volume precision and cushioning accuracy improve, but the device complexity and measurement system complexity increase
Solution Approach 1:
The optical detection system serves multiple functions: it measures encapsulant volume, verifies cushioning adequacy, and provides feedback for process control. By using a single optical system for multiple measurement and control purposes, the patent achieves high measurement precision without proportionally increasing system complexity.
Solution Approach 2:
The encapsulant material itself serves as the measurement medium by reflecting optical radiation. The system uses the inherent optical properties of the dispensed material to provide self-verification of volume and surface shape, eliminating the need for separate measurement instruments and reducing overall system complexity.
3Reliability
If encapsulant dispensing is optimized for precise volume control, then the lens cushioning quality improves, but the productivity and dispensing speed may deteriorate due to additional detection and control steps
Solution Approach 1:
The optical detection system operates continuously during the dispensing process, monitoring the encapsulant surface in real-time as material is deposited. This continuous measurement allows for immediate feedback and adjustment without interrupting the dispensing flow, maintaining high productivity while ensuring precise volume control and reliable cushioning quality.
Solution Approach 2:
The system establishes the target optical indicia pattern corresponding to the desired encapsulant volume before dispensing begins. During dispensing, the system compares real-time optical measurements against this pre-established target, enabling rapid decision-making and maintaining optimal dispensing speed while ensuring the final volume achieves the required cushioning quality.
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 ensures accurate dispensing of encapsulant material, maintaining the proper cushioning for the lens, thereby enhancing the performance and yield of semiconductor light emitting devices by compensating for variations in the dispensing apparatus and reflector cavity volume.
Implementation Method 1
detecting a predetermined shape of a surface of encapsulant material in a reflector cavity by reflecting optical radiation from the surface
Data Source
AI summary
A method of controlling dispensing of a liquid can include detecting a predetermined shape of a surface of a liquid in a container by reflecting optical radiation from the surface to control a volume of the liquid dispensed into the container. Related apparatus and computer program products are also disclosed.