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Conformal phosphor coating using pulsed spray to reduce color deviation of white LEDs

Hsin-Tao Huang, Chuang-Chuang Tsai, and Yi-Pai Huang

Open Access Open Access

Abstract

This work presents a novel “pulsed spray (PS)” process for the coating of yellow YAG:Ce3+ phosphor on blue InGaN-based light emitting diodes (LEDs). To coat a phosphor layer of high quality on an LED chip surface, the PS approach is used and studied because of the uniform color distribution, providing a wide range of color temperatures. This PS coating approach applies phosphor by exploiting mechanical principles without risk of chemical pollution. Additionally, it can be applied to wire-bonded LEDs and an array of LED chips on a substrate to fabricate a large-area, planar illumination system of high optical quality, which is easy to manufacture.

©2010 Optical Society of America

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Figures (8)
Fig. 1
Fig. 1 Schematic diagram of the phosphor coating process. (a) Conventional dispensing; (b) Pulsed Spray (PS).

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Fig. 2
Fig. 2 (a) The spectral properties of conformal phosphor coating using pulsed spray; (b) SEM morphology of YAG:Ce3+ phosphor.

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Fig. 3
Fig. 3 Phosphor coating using PS technique. (a) An array of blue LED chips on board (COB); (b) the magnification of individual LED.

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Fig. 4
Fig. 4 CIE 1976 chromaticity indices versus angular distribution of LED when the light is emitted at angles from −60° to + 60°. (a) Conventional dispensing; (b) conformal coating using PS.

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Fig. 5
Fig. 5 Relationship between phosphor loading (mg/cm2) and color temperature (Tc).

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Fig. 6
Fig. 6 CIE 1931 chromaticity indices versus angular distribution of LED at Tc centre around 9500 K. (a) Conventional dispensing; (b) conformal coating using PS.

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Fig. 7
Fig. 7 The CIE 1931 chromaticity diagram. Red triangle denotes the white point with different color temperature (Tc).

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Fig. 8
Fig. 8 SEM micrographs of phosphor coating using PS. (a) Top view; (b) cross-sectional view; (c) illuminated lighting module with phosphor coated by PS.

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Tables (1)

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Table 1 Optical comparison between conventional dispensing and CPC by PS a

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Equations (3)

Equations on this page are rendered with MathJax. Learn more.

u i ′ = 4 x i / ( - 2 x i + 12 y i + 3 ) , Š Δ u ' i = 1 - Δ u ' i = 2 , 3...
v i ′ = 9 y i / ( - 2 x i + 12 y i + 3 ) , Š Δ v ' i = 1 - Δ v ' i = 2 , 3...
Δ u ′ v ′ = ( ( Δ u ′ ) 2 + ( Δ v ′ ) 2 ) 1 / 2
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