Phosphor deposition method and apparatus for making light emitting diodes
First Claim
1. A method of depositing uniform layers of a matrix containing light converting materials onto light emitting diode chips, said method comprising the steps of:
- mixing at least one powder of a light converting material in a support matrix to provide a homogeneous mixture having a substantially uniform distribution of said material throughout;
introducing a carrier into said mixture of light converting material and support matrix to reduce the viscosity of said mixture for further processing;
atomizing said mixture; and
, depositing one or more layers of said mixture onto at least one light emitting diode chip to form at least one substantially uniform matrix layer containing said light converting material.
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Accused Products
Abstract
A phosphor deposition process and apparatus that enables an efficient, consistent, and flexible white light LED light engine by spraying a conformal coating of phosphor matrix onto an array of LEDs to achieve high color uniformity, consistency, and efficiency. A predetermined ratio of one or more phosphor powders are mixed with a support matrix (preferably silicone), the types and amounts of which are calculated to provide a predetermined spectral output. A low-viscosity carrier is introduced into the phosphor matrix to allow for further processing and deposition. The phosphor matrix and carrier mixture is atomized and sprayed in one or more uniform layers onto one or more LED devices. Computerized control, movable stages, and in-process spectral monitoring are incorporated to provide rapid and accurate processing of LED devices.
36 Citations
28 Claims
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1. A method of depositing uniform layers of a matrix containing light converting materials onto light emitting diode chips, said method comprising the steps of:
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mixing at least one powder of a light converting material in a support matrix to provide a homogeneous mixture having a substantially uniform distribution of said material throughout;
introducing a carrier into said mixture of light converting material and support matrix to reduce the viscosity of said mixture for further processing;
atomizing said mixture; and
,depositing one or more layers of said mixture onto at least one light emitting diode chip to form at least one substantially uniform matrix layer containing said light converting material. - View Dependent Claims (2)
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3. A method of depositing uniform layers of a phosphor containing matrix onto light emitting diode chips, said method comprising the steps of:
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mixing phosphor powder in a support matrix to provide a homogeneous mixture having a substantially uniform distribution of phosphor throughout;
introducing a carrier into said mixture of phosphor and support matrix to reduce the viscosity of said mixture for further processing;
atomizing said mixture; and
,depositing one or more layers of said mixture onto at least one light emitting diode chip to form at least one substantially uniform phosphor matrix layer. - View Dependent Claims (4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 25, 26, 27, 28)
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23. A method of depositing uniform layers of a phosphor containing matrix onto light emitting diode chips, said method comprising the steps of:
- mixing one or more phosphor powders in predetermined proportions so that the powder mixture has predetermined spectral properties;
mixing said one or more phosphor powders with a support matrix of sufficient viscosity to provide a homogeneous mixture in which said phosphor remains uniformly distributed within the mixture;
further mixing a carrier in said mixture to provide a thinned mixture of reduced viscosity that may be handled substantially as a liquid and wherein said carrier evaporates upon atomization;
pouring said thinned mixture into a fluid cup and agitating it to prevent said phosphor powders from settling within the cup;
pressurizing said cup and forcing said thinned mixture to flow to an atomizer;
atomizing said thinned mixture and directing said atomized thinned mixture onto a light emitting diode-to cause said carrier to evaporate while depositing one or more phosphor matrix layers on said light emitting diode;
recirculating residual undeposited thinned mixture back to said cup and said agitator to prevent phosphor from settling within said mixture;
encapsulating the one or more phosphor matrix layers on said light emitting diode so that the one or more phosphor matrix layers remain substantially stable and stationary.
- mixing one or more phosphor powders in predetermined proportions so that the powder mixture has predetermined spectral properties;
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24. An apparatus for depositing one or more layers of phosphorous matrix onto a light emitting diode, said apparatus comprising:
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a fluid cup for receiving and mixing predetermined amounts of;
phosphorous powders matrix material for suspending said phosphorous powder within it, and carrier solution for lowering the viscosity of the phosphorous mixture to a fluid-like state;
an agitator connected with said cup for agitating the phosphorous mixture to maintain a substantially consistent distribution of phosphor powder within said mixture;
a first air pressure supply line and fluid discharge line connected to said fluid cup where pressure from said first air pressure supply line forces said phosphorous mixture out through said fluid discharge line from said fluid cup;
a spray head for depositing said phosphorous mixture onto a light emitting diode, said spray head connected to said fluid cup by said fluid discharge line, said spray head having a spray nozzle for completing deposition of said phosphorous mixture by atomizing and spraying it onto the light emitting diode.
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Specification