Segmented LED Die for Precise Phosphor Deposition
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Solution Overview
Problem
Current color-changing LED technologies face challenges in achieving efficient color mixing and optical control due to the need for multiple LEDs and primary optics, which increases size, cost, and complexity, and struggles with phosphor deposition on closely spaced LED pixels leading to color variations and reduced tuneability.
Innovation Solution
A color-changing LED package with a single LED die composed of multiple segments emitting different colors, where each segment can be independently controlled, allowing for efficient color mixing and tuning, and using electrophoretic deposition of phosphors on discrete strings or blocks to minimize crosstalk and enhance color range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple individual LEDs of different colors are placed under a single primary optic, then color changing capability is achieved, but color mixing is difficult and beam control is worsened
Solution Approach 1:
The LED die is divided into multiple segments, each emitting a different color. This segmentation allows each segment to be independently controlled and simplifies the optical design by eliminating the need for complex color mixing mechanisms while maintaining color changing capability.
Solution Approach 2:
Multiple color-emitting segments are integrated into a single LED die structure, combining multiple functions into one component. This merging eliminates the need for separate LEDs and complex mixing optics, thereby simplifying the overall device while achieving color changing functionality.
2Adaptability or versatility
If multiple individual LEDs of different colors are each placed under their own primary optic, then color control is improved, but the number of optics increases and beam overlap is incomplete
Solution Approach 1:
Multiple color-emitting segments are integrated into a single LED die structure, combining multiple functions into one component. This merging eliminates the need for separate LEDs and complex mixing optics, thereby simplifying the overall device while achieving color changing functionality.
Solution Approach 2:
A single primary optic serves multiple color-emitting segments, making the optic multi-functional. This universal optic design eliminates the need for multiple separate optics while still achieving complete beam overlap and effective color control.
3Adaptability or versatility
If phosphors are deposited on closely spaced LED pixels, then color tuneability is improved, but phosphor crosstalk increases and color endpoints vary
Solution Approach 1:
The LED die is divided into spatially separated segments with dedicated phosphor deposition zones. This segmentation creates physical barriers that prevent phosphor crosstalk between adjacent segments, ensuring precise phosphor placement and consistent color endpoints while maintaining color tuneability.
Solution Approach 2:
Each segment has its own dedicated phosphor deposition area with controlled phosphor distribution. This local quality control ensures that phosphor is deposited only where needed, preventing crosstalk with adjacent segments and maintaining precise color control for each segment.
4Area of stationary object
If a single LED die with multiple segments is used, then the number of optics is reduced and size is decreased, but phosphor crosstalk between segments may occur
Solution Approach 1:
The LED die is divided into spatially separated segments with dedicated phosphor deposition zones. This segmentation creates physical barriers that prevent phosphor crosstalk between adjacent segments, ensuring precise phosphor placement and consistent color endpoints while maintaining color tuneability.
Solution Approach 2:
Each segment has its own dedicated phosphor deposition area with controlled phosphor distribution. This local quality control ensures that phosphor is deposited only where needed, preventing crosstalk with adjacent segments and maintaining precise color control for each segment.
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 enables better optical control with a smaller optic, reducing cost and form factor, while improving color tuneability and reducing phosphor crosstalk, allowing for dynamic lighting effects and precise color adjustment.
Implementation Method 1
phosphors are applied by electrophoretic deposition (EPD) to specific junctions
Implementation Method 2
A voltage can be applied to specific groups of electrically connected junctions to form wavelength converters
Data Source
AI summary
A method to produce a light-emitting device package includes mounting junctions on pads of a metalized substrate, where the junctions are at least partially electrically insulated from each other, and forming wavelength converters, where each wavelength converter is located over a different junction and separated by a gap from neighboring wavelength converters.