High density pixelated LED and devices and methods thereof
First Claim
1. A multi-LED chip comprising:
- an array of LEDs supported by a substrate and arranged to transmit LED emissions through a plurality of light-transmissive portions of the substrate;
at least one lumiphoric material arranged on or over a light extraction surface of the substrate, wherein the at least one lumiphoric material is configured to receive at least a portion of the LED emissions and responsively generate lumiphor emissions, and wherein the at least one lumiphoric material comprises a plurality of light output areas substantially registered with the plurality of light-transmissive portions; and
a plurality of light segregation elements arranged at least partially within the substrate, wherein light segregation elements of the plurality of light segregation elements are arranged between different light-transmissive portions of the plurality of light-transmissive portions, and the plurality of light segregation elements is configured to reduce passage of LED emissions between the different light-transmissive portions;
wherein the multi-LED chip comprises at least one of the following features (i) or (ii);
(i) the substrate comprises a light injection surface that opposes the light extraction surface;
a first group of light segregation elements of the plurality of light segregation elements extends from the light injection surface into an interior of the substrate; and
a second group of light segregation elements of the plurality of light segregation elements extends from the light extraction surface into the interior of the substrate;
or(ii) the plurality of light segregation elements includes internal portions extending from an interior of the substrate to the light extraction surface, and includes external portions extending beyond the light extraction surface.
3 Assignments
0 Petitions
Accused Products
Abstract
At least one array of LEDs (e.g., in a flip chip configuration) is supported by a substrate having a light extraction surface overlaid with at least one lumiphoric material. Light segregation elements registered with gaps between LEDs are configured to reduce interaction between emissions of different LEDs and/or lumiphoric material regions to reduce scattering and/or optical crosstalk, thereby preserving pixel-like resolution of the resulting emissions. Light segregation elements may be formed by mechanical sawing or etching to define grooves or recesses in a substrate, and filling the grooves or recesses with light-reflective or light-absorptive material. Light segregation elements external to a substrate may be defined by photolithographic patterning and etching of a sacrificial material, and/or by 3D printing.
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Citations
26 Claims
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1. A multi-LED chip comprising:
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an array of LEDs supported by a substrate and arranged to transmit LED emissions through a plurality of light-transmissive portions of the substrate; at least one lumiphoric material arranged on or over a light extraction surface of the substrate, wherein the at least one lumiphoric material is configured to receive at least a portion of the LED emissions and responsively generate lumiphor emissions, and wherein the at least one lumiphoric material comprises a plurality of light output areas substantially registered with the plurality of light-transmissive portions; and a plurality of light segregation elements arranged at least partially within the substrate, wherein light segregation elements of the plurality of light segregation elements are arranged between different light-transmissive portions of the plurality of light-transmissive portions, and the plurality of light segregation elements is configured to reduce passage of LED emissions between the different light-transmissive portions; wherein the multi-LED chip comprises at least one of the following features (i) or (ii); (i) the substrate comprises a light injection surface that opposes the light extraction surface;
a first group of light segregation elements of the plurality of light segregation elements extends from the light injection surface into an interior of the substrate; and
a second group of light segregation elements of the plurality of light segregation elements extends from the light extraction surface into the interior of the substrate;
or(ii) the plurality of light segregation elements includes internal portions extending from an interior of the substrate to the light extraction surface, and includes external portions extending beyond the light extraction surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A multi-LED chip comprising:
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an array of LEDs; at least one lumiphoric material, wherein the at least one lumiphoric material is configured to receive at least a portion of LED emissions and responsively generate lumiphor emissions, wherein the at least one lumiphoric material comprises a plurality of light output areas; and a plurality of light segregation elements registered with boundaries between at least some LEDs of the array of LEDs; wherein the at least one lumiphoric material overlaps a portion of each light segregation element of the plurality of light segregation elements; and wherein a plurality of voids is defined in the at least one lumiphoric material, and each void of the plurality of voids is registered with a different light segregation element of the plurality of light segregation elements. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22)
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23. A multi-LED chip comprising:
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a functional stack comprising a plurality of semiconductor layers and an active region; an array of LEDs formed in the functional stack and defining a plurality of pixels, wherein each LED of the array of LEDs comprises a light-transmissive substrate material portion arranged over the active region; a plurality of light segregation elements registered with boundaries between at least some pixels of the plurality of pixels, the plurality of light segregation elements comprising reflective material arranged between substrate material portions of different LEDs of the array of LEDs; and an underfill material registered with boundaries between at least some pixels of the plurality of pixels; wherein the underfill material extends continuously in a lateral direction between active regions of each LED of the array of LEDs; and wherein the plurality of light segregation elements comprises at least one recess configured to expose the underfill material. - View Dependent Claims (24, 25, 26)
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Specification