LED WITH PHOSPHOR TILE AND OVERMOLDED PHOSPHOR IN LENS
2 Assignments
0 Petitions
Accused Products
Abstract
Overmolded lenses and certain fabrication techniques are described for LED structures. In one embodiment, thin YAG phosphor plates are formed and affixed over blue LEDs mounted on a submount wafer. A clear lens is then molded over each LED structure during a single molding process. The LEDs are then separated from the wafer. The molded lens may include red phosphor to generate a warmer white light. In another embodiment, the phosphor plates are first temporarily mounted on a backplate, and a lens containing a red phosphor is molded over the phosphor plates. The plates with overmolded lenses are removed from the backplate and affixed to the top of an energizing LED. A clear lens is then molded over each LED structure. The shape of the molded phosphor-loaded lenses may be designed to improve the color vs. angle uniformity. Multiple dies may be encapsulated by a single lens. In another embodiment, a prefabricated collimating lens is glued to the flat top of an overmolded lens.
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Citations
56 Claims
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1-12. -12. (canceled)
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13. A light emitting diode (LED) structure comprising:
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an LED emitting blue light or UV light on a submount; a substantially flat phosphor layer overlying the LED; a molded phosphor-loaded lens over the phosphor layer; and a clear lens, containing no phosphor, molded over the LED and phosphor-loaded lens. - View Dependent Claims (14, 15, 16, 17, 18, 19)
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20-22. -22. (canceled)
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23. A light emitting diode (LED) structure comprising:
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an LED emitting blue light or UV light on a submount; a molded first phosphor-loaded lens containing a first phosphor over the LED; a molded second phosphor-loaded lens containing a second phosphor over the first phosphor-loaded lens; a molded clear lens, containing no phosphor over the second phosphor-loaded lens. - View Dependent Claims (24, 25)
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26. A light emitting diode (LED) structure comprising:
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an LED on a submount along with one or more semiconductor dice mounted on the submount; and a single lens molded over the LED and the one or more semiconductor dice. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33)
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34. A light emitting diode (LED) structure comprising:
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an LED mounted on a substrate; a first lens molded over and encapsulating the LED, the lens having a substantially flat top; and a prefabricated second lens affixed to the substantially flat top of the first lens. - View Dependent Claims (35, 36, 37, 38, 39, 40, 41, 42, 43)
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44. A process for forming a light emitting diode (LED) structure comprising:
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mounting an LED on a submount, wherein at least a first electrode on the LED is bonded to at least a second electrode on a surface of the submount, a void existing between the LED and the surface of the submount; filling the void with an underfill material; providing a mold having an indention corresponding to a lens; filling the indention with a liquid lens material; after the step of filling, immersing the LED and the underfill material into the liquid lens material in the mold, the underfill preventing the liquid lens material from entering the void; curing the liquid lens material to encapsulate the LED and underfill material with a molded lens; and removing the LED with the molded lens from the mold. - View Dependent Claims (45)
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46-49. -49. (canceled)
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50. A light emitting diode (LED) structure comprising:
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an LED on a submount; a molded first lens over the LED, wherein the molded first lens has a plasma treated outer surface; a molded second lens formed directly over the first lens, wherein the plasma treated outer surface of the first lens increases adherence of the first lens to the second lens.
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51. A process for forming a light emitting diode (LED) structure comprising:
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providing an arrangement of a plurality of LED dies mounted on a single submount substrate; providing a first mold having first indentions in an arrangement corresponding to the arrangement of the plurality of LED dies, each first indentation corresponding to outer dimensions of a first lens to be formed over each of the LED dies mounted on the submount substrate; aligning the submount substrate with respect to the first mold; molding first lenses, not containing a phosphor, directly over each of the LED dies using the first mold; providing a second mold having second indentions in an arrangement corresponding to the arrangement of the plurality of LED dies, each second indentation corresponding to outer dimensions of a second lens to be formed over each of the LED dies mounted on the submount substrate, dimensions of each second indention being larger than dimensions of each first indention; aligning the submount substrate with respect to the second mold; and molding second lenses, containing a phosphor, over each of the LED dies and first lenses using the second mold; whereby inner dimensions of the second lenses over the LED dies are defined by outer dimensions of the first lenses over the LED dies, such that identical misalignments of the submount substrate with respect to the first mold and the second mold, within a range, do not affect a thickness of the second lenses. - View Dependent Claims (52, 53, 54, 55)
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56. A light emitting diode (LED) structure comprising:
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an LED die mounted on a submount substrate; a first lens molded directly over the LED die using a first mold aligned to the substrate, the first lens containing no phosphor; and a second lens molded directly over the first lens using a second mold aligned to the substrate, the second lens containing a phosphor, whereby inner dimensions of the second lens over the LED die are defined by outer dimensions of the first lens over the LED die, such that identical misalignments of the substrate with respect to the first mold and the second mold, within a range, do not affect a thickness of the second lens.
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Specification