LED production method and LEDs
First Claim
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1. A method for producing LEDs, the LEDs being LEDs obtained by coating LED chips on an LED substrate with a phosphor, the method comprising:
- a first step of forming a mask having openings and adhered to the LED substrate for filling a binder-rich first slurry containing at least a phosphor and a binder to at least peripheries of the LED chips;
a second step of filling the first slurry to at least the peripheries of the LED chips in such a manner that a level of the filled first slurry falls within a range of ±
30 micrometers from heights of the LED chips; and
a third step of filling or applying a phosphor-rich second slurry containing at least a phosphor and a binder onto at least the LED chips.
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Abstract
Provided is an LED production method that can produce a great number of high-quality LEDs at low production cost. A binder-rich layer is formed on LEDs to increase the adhesiveness between the LEDs and a substrate; a phosphor layer or phosphor-rich layer is formed over the layer with a mask put on the layer; and the phosphor or a mixture of the phosphor and binder on the mask is recovered and reused.
11 Citations
10 Claims
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1. A method for producing LEDs, the LEDs being LEDs obtained by coating LED chips on an LED substrate with a phosphor, the method comprising:
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a first step of forming a mask having openings and adhered to the LED substrate for filling a binder-rich first slurry containing at least a phosphor and a binder to at least peripheries of the LED chips; a second step of filling the first slurry to at least the peripheries of the LED chips in such a manner that a level of the filled first slurry falls within a range of ±
30 micrometers from heights of the LED chips; anda third step of filling or applying a phosphor-rich second slurry containing at least a phosphor and a binder onto at least the LED chips. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. LEDs obtained by a manufactured method comprising:
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a first step of causing a first mask having openings corresponding to LED chips on an LED substrate to adhere to the LED substrate; a second step of filling a binder-rich first slurry containing at least a phosphor and a binder to at least peripheries of the LED chips in such a manner that a level of the filled first slurry falls within a range of ±
30 micrometers from heights of the LED chips; anda third step of filling or applying a phosphor-rich second slurry containing at least a phosphor, a binder, and a solvent to at least the LED chips a plurality of times. - View Dependent Claims (9)
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10. LEDs that are chip-on-board (COB) LEDs, obtained by a manufactured method comprising:
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a first step of filling a binder-rich first slurry containing at least a phosphor and a binder to at least peripheries of LED chips in such a manner that a level of the filled first slurry falls within a range of ±
30 micrometers from heights of the LED chips;a second step of facilitating curing of the binder of the first slurry; and a third step of filling or applying a phosphor-rich second slurry containing at least a phosphor, a binder, and a solvent to at least the LED chips.
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Specification