White LED Device with Sandwiched Phosphor Layer
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Solution Overview
Problem
Current white light emitting diode devices face issues with uneven phosphor distribution and complex manufacturing processes due to direct application of a binding agent containing phosphors over the LED chip, leading to chromatic aberration and the need for specific phosphor selection based on varying LED wavelengths.
Innovation Solution
A white light emitting diode device design that uses a light-pervious binding agent containing phosphors sandwiched between two transparent sheets, which are then fixed over a base case with a fillister and rabbet, ensuring even phosphor distribution and simplifying the manufacturing process by allowing for separate production of the covering element and base case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the LED chip is directly covered with the binding agent containing phosphor, then the manufacturing process is simplified, but the phosphor distribution becomes uneven causing chromatic aberration
Solution Approach 1:
The patent divides the covering element into multiple separate transparent sheets instead of applying binding agent directly as a single layer. This segmentation allows the phosphor-containing binding agent to be distributed evenly between the sheets, achieving uniform phosphor distribution while maintaining manufacturing simplicity.
2Reliability
If different phosphors and concentrations are selected based on LED wavelength variations, then the desired white light output is achieved, but the manufacturing process becomes complex
Solution Approach 1:
The patent creates a universal covering element structure with multiple transparent sheets that can accommodate different phosphor types and concentrations. This standardized multi-sheet design allows flexibility in phosphor selection based on LED wavelength variations without requiring complex manufacturing processes, as the same structural approach works for all configurations.
3Device complexity
If the LED chip is directly covered with phosphor-containing binding agent, then the device structure is simplified, but numerous complicated procedures are required in operation
Solution Approach 1:
The patent prepares the phosphor-containing binding agent and positions it between transparent sheets in advance, before final assembly with the LED chip. This preliminary preparation ensures even phosphor distribution is achieved beforehand, eliminating the need for complex adjustment procedures during operation and simplifying the overall device assembly process.
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 design achieves even phosphor distribution and simplifies the production process, reducing chromatic aberration and manufacturing complexity, while enabling the creation of various white light outputs such as daylight and warm white light with reduced waste and lower costs.
Implementation Method 1
phosphors contained in the binding agent is excited by the light source emitted from the light emitting diode and generates white light emitted from the device
Data Source
AI summary
The present invention relates to a white light emitting diode device, which comprises a light emitting diode device; a base case, which is provided with a fillister for placing the LED and a rabbet; and a covering element, which is installed over the fillister and fixed on the rabbet and consists of two transparent sheets; wherein a light-pervious binding agent containing phosphors is sandwiched between the two transparent sheets, thereby phosphors contained in the binding agent is excited by the light source emitted from the light emitting diode and generates white light emitted from the device.