Phosphor Sheet Manufacturing via Compression Molding
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Solution Overview
Problem
Conventional methods for manufacturing phosphor sheets result in uneven phosphor distribution and light emission due to non-uniform centrifugal distribution, leading to variations in luminescence chromaticity and emission spectrum.
Innovation Solution
A method involving mixing particulate phosphor and transparent medium with a light transmissive resin, followed by compression molding to achieve a uniform phosphor sheet with a barrier layer, ensuring consistent light emission and reduced spectral variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If centrifugal force is used to spin down phosphor in transparent resin, then phosphor distribution should be uniform, but phosphor of each color sometimes thickens causing unevenness of light emission
Solution Approach 1:
The patent changes the physical state parameter of the resin from liquid to gel state before centrifugal spinning. This gel state provides a semi-solid matrix that prevents phosphor particles from migrating and thickening during centrifugal force application, while still allowing sufficient distribution. The gelification process transforms the resin's viscosity and flow properties, enabling uniform phosphor embedding without the aggregation problems that occur in liquid state processing.
2Manufacturing precision
If centrifugal force is applied to distribute phosphor, then chromaticity variation should be reduced, but phosphor concentration variation occurs
Solution Approach 1:
The patent performs gelification of the transparent resin before applying centrifugal force to distribute the phosphor particles. This preliminary action creates a semi-solid gel matrix that maintains fixed phosphor concentrations in each region, preventing the concentration variations that would otherwise occur during centrifugal processing. The gel structure locks the phosphor particles in place while still allowing for controlled distribution.
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 method produces a phosphor sheet with a uniform emission spectrum and improved light absorption efficiency, reducing film thickness variations and enhancing optical stability, resulting in a high-quality phosphor sheet suitable for LED devices.
Implementation Method 1
The first light transmissive resin containing the phosphor and the transparent medium in the liquid state is changed to a solid state having a predetermined thickness by applying a heat and a pressure
Data Source
AI summary
A method for manufacturing a phosphor sheet is provided. In the method, a particulate phosphor and a particulate transparent medium are mixed to a first light transmissive resin in a liquid state. The first light transmissive resin containing the phosphor and the transparent medium in the liquid state is supplied into a lower mold of a mold, and the mold is closed. The first light transmissive resin containing the phosphor and the transparent medium in the liquid state is changed to a solid state having a predetermined thickness by applying a heat and a pressure to the first light transmissive resin containing the phosphor and the transparent medium in the liquid state.