Segmented Ceramic LED Conversion Plate for Color Control
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Solution Overview
Problem
Existing LED modules with stacked ceramic layers for wavelength conversion require specific phosphor concentrations and thicknesses for each color point, leading to color variation with viewing angle and increased device thickness, and risk of light absorption.
Innovation Solution
A ceramic conversion plate divided into lateral segments with wavelength-converting materials allows for reduced thickness and color variation by placing segments side by side, enabling flexible color adjustment through position and size selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple ceramic layers are stacked over the light emitting layer, then different phosphors can be combined to control color point, but the device thickness increases significantly
Solution Approach 1:
The patent transitions from a vertical stacking arrangement (multiple layers in the thickness direction) to a lateral arrangement (multiple segments in the planar direction). This dimensional change allows multiple phosphors to be positioned side-by-side rather than stacked, thereby achieving color control without increasing device thickness.
Solution Approach 2:
The conversion plate is divided into multiple segments, each containing different phosphors. These segments are arranged laterally adjacent to each other in the same plane, allowing independent optical paths for each phosphor while maintaining a compact overall structure.
2Adaptability or versatility
If multiple ceramic layers are stacked, then color control is achieved, but color variation occurs with viewing angle
Solution Approach 1:
By arranging phosphor-containing segments laterally in the same plane rather than stacking them vertically, the patent eliminates the viewing-angle-dependent optical path length variations that occur in stacked structures. Light from each segment travels a relatively consistent path to the observer regardless of viewing angle.
Solution Approach 2:
Each segment is designed with specific phosphor concentrations and compositions tailored to its local function, allowing optimized color emission from each segment while maintaining overall color consistency across different viewing angles.
3Adaptability or versatility
If multiple ceramic layers are stacked with specific phosphor concentrations, then desired color point is achieved, but the manufacturing complexity increases for each color point
Solution Approach 1:
The conversion plate is segmented into multiple regions, each containing different phosphors. This segmentation allows for standardized manufacturing of individual segments that can be laterally arranged in different configurations to achieve various color points, simplifying the manufacturing process compared to creating unique stacked layer combinations for each color point.
Solution Approach 2:
A single segmented conversion plate design can serve multiple functions by laterally arranging segments in different patterns or selecting different segments to be active, enabling the same basic structure to achieve multiple color points without requiring separate manufacturing processes for each.
4Use of energy by moving object
If ceramic layers are stacked, then wavelength conversion is achieved, but light from lower layers may be absorbed by upper layers
Solution Approach 1:
By arranging phosphor segments laterally in the same plane rather than stacking them vertically, the patent creates independent optical paths for light from each segment. This eliminates the problem of upper layers absorbing light from lower layers, as each segment emits light that travels directly to the observer without passing through other phosphor-containing layers.
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 configuration allows for a wide range of color points with a single ceramic conversion plate configuration, reducing device thickness and color variation over viewing angles, and enabling efficient light mixing for desired color outputs.
Implementation Method 1
light of a first (peak) wavelength can be converted into light of a longer (peak) wavelength using a process known as luminescence/fluorescence. The fluorescent process involves absorbing the light having the first wavelength by a wavelength-converting material such as a phosphor, exciting the luminescent centers of the phosphor material, which emit the light of the longer wavelength.
Data Source
AI summary
The present invention relates to a light emitting diode (LED) module (10), comprising at least one LED chip (12) having a surface (13) for emitting light, and a ceramic conversion plate (14). The LED module is characterized in that the ceramic conversion plate includes a first segment (18) covering a first portion of the light emitting surface of the LED chip(s) and a second segment (20) provided alongside the first segment covering a second portion of the light emitting surface of the LED chip(s), wherein at least one of the segments comprises a wavelength-converting material for converting light emitted from the LED chip(s) to a certain wavelength. The present invention also relates to a method for the manufacturing of such an LED module, and a ceramic conversion plate for use in an LED module.