Manufacturing method for LED emitter with high color consistency

1. A method for forming light emitters with multiple LEDs (light-emitting-diodes), wherein the number of LEDs in each emitter is an integer M, the method comprising:

determining color coordinates CIEx and CIEy and intensity for each of a plurality of LEDs, wherein CIEx and CIEy are color coordinates in a CIE chromaticity diagram, and wherein N is the number of LEDs in the plurality of LEDs;

determining a first parameter X 0 and a second parameter Y 0 for a target light color, wherein X 0 and Y 0 are related to CIEx and CIEy of each of the N LEDs and a weighting factor related to the intensity of each of the N LEDs;

for each possible group of M LEDs out of the N LEDs in the plurality of LEDs:

determining a first group parameter X and a second group parameter Y, wherein X and Y are related to CIEx and CIEy of each of the M LEDs and a weighting factor related to the intensity of each of the M LEDs; and

determining a difference between the first and second group parameters X and Y of each LED in the group of M LEDs and X 0 and Y 0 ;

selecting a first group of M LEDs whose first group parameter X and second group parameter Y are closest to X 0 and Y 0 as a first candidate for forming a light emitter with M LEDs;

removing the selected first group of M LEDs from the plurality of LEDs; and

for the LEDs remaining in the plurality of LEDs, repeating the above processes to select a group of M LEDs as the next candidate for forming a light emitter.

2. The method of claim 1 , wherein the weighting factor is related to the lumen of the LEDs.

3. The method of claim 2 , wherein the weighting factor is related to a ratio of lumen over CIE-y of each LED.

4. The method of claim 1 , wherein the weighting factor is related to radiant power of the LEDs.

5. The method of claim 4 , wherein the first parameter X 0 of the target light color is related to a sum of the CIEx of each of N LEDs multiplied by a ratio of the radiant power of each of the N LEDs divided by a sum of the radiant power of all N LEDs, and the second parameter Y 0 of the target light color is related to a sum of the CIEy of each of N LEDs multiplied by a ratio of the radiant power of each of the N LEDs divided by a sum of the radiant power of all N LEDs.

6. The method of claim 4 , wherein the first group parameter X of each of the possible groups of M LEDs is related to a sum of the CIEx of each of M LEDs multiplied by a ratio of the radiant power of each of the M LEDs divided by a sum of the radiant power of all M LEDs in that group, and the second group parameter Y of each of the possible groups of M LEDs is related to a sum of the CIEy of each of M LEDs multiplied by a ratio of the radiant power of each of the M LEDs divided by a sum of the radiant power of all M LEDs in that group.

7. The method of claim 1 , wherein selecting the first group of M LEDs comprises:

calculating a root mean square difference between (X, Y) and (X 0 , Y 0 ), wherein X and Y are the first and the second group parameters for each of the possible groups of M LEDs, and X 0 and Y 0 are first and the second parameters of the target light color, and

selecting a group with the minimum root mean square difference.

8. The method of claim 1 , wherein each of the LEDs comprises an LED chip having a phosphor-containing material disposed thereon.

9. The method of claim 8 , wherein each of the LEDs comprises a blue LED having a phosphor-containing material including a green phosphor and a red phosphor disposed thereon.

10. The method of claim 8 , wherein each of the LEDs comprises a blue LED having a phosphor-containing material including a yellow phosphor and a red phosphor disposed thereon.

11. A method for forming multiple-LED (light-emitting-diode) light emitters from a plurality of LEDs, the method comprising:

characterizing the plurality of LEDs according to first and second parameters of each LED, the first and second parameters being related to color coordinates CIEx and CIEy, respectively;

determining a target color, which is characterized by a first and second parameters, X 0 and Y 0 , that are related to color coordinates CIEx and CIEy in a chromaticity diagram;

for all possible combinations of M LEDs out of the LEDs in the plurality of LEDs:

determining a first group parameter X and a second group parameter Y based on the first and second parameters for each of the M LEDs in the group; and

determining a difference between the first and second parameters of each group and X 0 and Y 0 ;

selecting a group of M LEDs that has the smallest difference as a candidate for forming a light emitter of M LEDs.

12. The method of claim 11 , further comprising:

removing the selected group of M LEDs from the plurality of LEDs; and

for the remaining LEDs, repeating the process of selecting a group of M LEDs for forming a multiple-LED emitter.

13. The method of claim 11 , wherein the first parameter X 0 and the second parameter Y 0 for the target light color is further related to a weighting factor related to the intensity of each of the plurality of LEDs.

14. The method of claim 13 , wherein the weighting factor is related to the lumen of the LEDs.

15. The method of claim 13 , wherein each of the weighting factor is related to a ratio of lumen over CIE-y of each LED.

16. The method of claim 13 , wherein the weighting factor is related to the radiant power of the LEDs.

17. The method of claim 11 , wherein the first group parameter X and the second group parameter Y for the group of M LEDs is further related to a weighting factor related to the intensity of each of the M LEDs.

18. The method of claim 17 , wherein the weighting factors are related to the lumen of the LEDs.

19. The method of claim 17 , wherein the weighting factors are related to the radiant power of the LEDs.

20. The method of claim 11 , wherein each of the LEDs comprises an LED chip having a phosphor-containing material disposed thereon.