A new manufacturing method of white LED module developed by IDEC

In the pseudo white LED module and yellow phosphor blue LED element, Japan Idec company (IDEC) has developed a new manufacturing process can achieve stable quality and simplify the working procedure, gelatinous silicon resin sheet only needs to be covered in LED phosphor containing heating element, can be encapsulated LED components, compared with the method of manufacture the original by pouring liquid resin to encapsulate the package can be required process time is shortened to 1/9.

Pouring liquid resin to a method for manufacturing a package to LED around the element on the substrate for forming a barrier resin flowing out of the "Ba", then mixing resin and phosphor, pouring onto the substrate, and finally heat hardening. In this manufacturing method, there are many problems, such as the uneven mixing of resin and phosphor, the precipitation of phosphor in the resin, the amount of resin pouring and so on. If the quality of the packaging process is not uniform, the color deviation will be produced.

White LED module with new manufacturing method. Encapsulation of LED elements by heating a gelatinous silicone resin sheet covered with a yellow phosphor on a blue LED element.

Gel like silicone resin sheet containing yellow phosphor. Silicone is generally not able to maintain the gel state, this time by improving the molecular structure to maintain the gel state.

The new manufacturing method is to cover the gel resin sheet on the LED element and heat up to about 150 DEG C, and the sheet is hardened after a period of about 40 minutes. In the past, it is necessary to complete the encapsulation process (from the formation of the dam to the thermal hardening) by pouring the liquid resin to 6 hours. In the new manufacturing method, because the sheet is gelatinous, the phosphor will not precipitate, and the uneven quality of the packaging process is greatly reduced. And production equipment is also expected to significantly simplify.

The gel resin sheet by ensequence development. Ensequence is selling this sheet to other companies other than Edyk. Edyk used the sheet to establish a new manufacturing method and developed a white LED module. Edyk will use white LED lighting module production to the factory in the year 2013 in Hamamatsu, plans will be replaced with a new manufacturing method of all modules.