Phosphor Plate Protrusion Design for LED Luminous Flux
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Solution Overview
Problem
Phosphor plates for LEDs suffer from structural defects like pore formation and phosphor separation during manufacturing processes, leading to reduced luminous flux and degraded color quality.
Innovation Solution
A phosphor plate design featuring a base plate with a protrusion part that accounts for 20% to 70% of its surface area, where the phosphor is compression-molded and sintered to maintain its integrity during polishing, preventing separation and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass frit is sintered to manufacture phosphor plate, then the phosphor plate structure is formed, but structural defects such as pore formation occur reducing strength
Solution Approach 1:
The patent changes the manufacturing parameters by controlling sintering temperature (900-1100°C) and time (30-120 minutes) to optimize the glass frit sintering process, reducing pore formation while maintaining structural integrity
Solution Approach 2:
The patent uses composite materials by combining glass frit with specific phosphor particles (YAG:Ce, LuAG:Ce, or nitride phosphors) in controlled ratios, creating a composite structure that maintains strength while enabling the desired optical properties
2Manufacturing precision
If abrasive polishing is performed on phosphor plate, then surface smoothness is improved, but phosphor separation and damage occur
Solution Approach 1:
The patent applies preliminary action by pre-coating the phosphor plate surface with a protective layer before polishing, or by pre-optimizing the phosphor-glass matrix bonding to prevent phosphor particle detachment during the polishing process
Solution Approach 2:
The patent changes polishing parameters by using controlled polishing pressure, duration (5-30 minutes), and abrasive particle size to achieve surface smoothness while minimizing phosphor removal through optimized material removal rates
3Productivity
If phosphor is damaged or separated during processing, then manufacturing is completed, but luminous flux and color quality are degraded
Solution Approach 1:
The patent uses composite materials with specific phosphor-glass matrix compositions and bonding mechanisms to maintain phosphor particle integrity during processing while achieving the desired luminous properties
Solution Approach 2:
The patent optimizes processing parameters including sintering temperature (900-1100°C), polishing pressure and duration, and phosphor particle size distribution to prevent phosphor damage while maintaining manufacturing efficiency
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
The solution enhances luminous flux and color homogeneity by preserving the phosphor's original shape and structure, reducing surface roughness and phosphor loss, thereby improving the phosphor plate's luminous efficiency and color quality.
Implementation Method 1
a phosphor included in the base plate
Data Source
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AI summary
The present invention relates to a phosphor plate comprising: a base plate; and phosphor included in the base plate, and provides a phosphor plate and a method for manufacturing the same, wherein one side of the phosphor plate comprises: a protrusion part formed by protrusion of the phosphor fixed to the base plate; and a recess part formed by separation of the phosphor from the base plate, the protrusion part being 20 to 70% with respect to the area of one side of the phosphor plate.