LIGHT-EMITTING DIES INCORPORATING WAVELENGTH-CONVERSION MATERIALS AND RELATED METHODS

• US 20130187174A1
• Filed: 02/15/2013
• Published: 07/25/2013
• Est. Priority Date: 01/24/2012
• Status: Active Grant

• Current Assignee: Epistar Corporation
• Original Assignee: Cooledge Lighting Inc.
• Inventors: Tischler, Michael A.
• Granted Patent: US 8,629,475 B2
• Time in Patent Office: Days
• US Class Current: 257/80
• CPC Class Codes: H01L 21/00 Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
• CPC Class Codes: H01L 2224/13022 the bump connector being at least partially embedded in the surface
• CPC Class Codes: H01L 2224/16145 the bodies being stacked
• CPC Class Codes: H01L 2224/73259 Bump and HDI connectors
• CPC Class Codes: H01L 24/96 the devices being encapsulated in a common layer, e.g. neo-wafer or pseudo-wafer, said common layer being separable into individual assemblies after connecting
• CPC Class Codes: H01L 24/97 the devices being connected to a common substrate, e.g. interposer, said common substrate being separable into individual assemblies after connecting
• CPC Class Codes: H01L 25/00 Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereofdevices consisting of a plurality of solid state components formed in or on a common substrate H01L27/00; photovoltaic modules or arrays of photovoltaic cells H01L31/042 ; panels or arrays of photo electrochemical cells H01G9/2068
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 27/14 including semiconductor components sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation radiation-sensitive components structurally associated with one or more electric light sources only H01L31/14; couplings of light guides with optoelectronic elements G02B6/42
• CPC Class Codes: H01L 29/00 Semiconductor devices specially adapted for rectifying, amplifying, oscillating or switching and having potential barriers; Capacitors or resistors having potential barriers, e.g. a PN-junction depletion layer or carrier concentration layer; Details of semiconductor bodies or of electrodes thereof ; Multistep manufacturing processes therefor H01L31/00 - H01L33/00, H10K10/00, H10N take precedence; details other than of semiconductor bodies or of electrodes thereof H01L23/00; devices consisting of a plurality of solid state components formed in or on a common substrate H01L27/00
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/01005 Boron [B]
• CPC Class Codes: H01L 2924/07802 not being an ohmic electrical conductor
• CPC Class Codes: H01L 2924/07811 Extrinsic, i.e. with electrical conductive fillers
• CPC Class Codes: H01L 2924/12032 Schottky diode
• CPC Class Codes: H01L 2924/12041 LED
• CPC Class Codes: H01L 2924/12042 LASER
• CPC Class Codes: H01L 2924/12043 Photo diode
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 2924/1815 Shape
• CPC Class Codes: H01L 2933/0033 : relating to semiconductor body packages
• CPC Class Codes: H01L 2933/0041 : relating to wavelength conversion elements
• CPC Class Codes: H01L 31/0203 : Containers; Encapsulations , e.g. encapsulation of photodiodesfor photovoltaic devices H01L31/048; for organic photosensitive devices H10K30/80
• CPC Class Codes: H01L 31/022425 : for solar cells
• CPC Class Codes: H01L 31/02322 : comprising luminescent members, e.g. fluorescent sheets upon the device
• CPC Class Codes: H01L 31/02327 : the optical elements being integrated or being directly associated to the device, e.g. back reflectors optical coatings H01L31/0216
• CPC Class Codes: H01L 31/048 : Encapsulation of modules
• CPC Class Codes: H01L 31/055 : where light is absorbed and re-emitted at a different wavelength by the optical element directly associated or integrated with the PV cell, e.g. by using luminescent material, fluorescent concentrators or up-conversion arrangements
• CPC Class Codes: H01L 33/486 : adapted for surface mounting
• CPC Class Codes: H01L 33/501 : characterised by the materials, e.g. binder
• CPC Class Codes: H01L 33/505 : characterised by the shape, e.g. plate or foil
• CPC Class Codes: H01L 33/60 : Reflective elements
• CPC Class Codes: H05B 33/02 : Details
• CPC Class Codes: H05B 33/12 : Light sources with substantially two-dimensional radiating surfaces
• CPC Class Codes: Y02E 10/52 : PV systems with concentrators

Abstract

In accordance with certain embodiments, semiconductor dies are embedded within polymeric binder to form, e.g., freestanding white light-emitting dies and/or composite wafers containing multiple light-emitting dies embedded in a single volume of binder.

Claims

1-122. -122. (canceled)

123. An electronic device comprising:

a solid shaped volume of a polymeric binder;

suspended within the binder, a semiconductor die having a first face, a second face opposite the first face, and at least one sidewall spanning the first and second faces; and

disposed on the first face of the semiconductor die, at least two spaced-apart contacts each having a free terminal end (i) not covered by the binder and (ii) available for electrical connection.

124. The electronic device of claim 123, wherein at least portions of the contacts protrude from the binder.

125. The electronic device of claim 123, wherein at least a portion of each said sidewall protrudes from the binder.

126. The electronic device of claim 123, wherein the binder defines a rectangular solid having approximately 90°

corners between adjacent faces thereof.

127. The electronic device of claim 123, wherein the binder comprises at least one of silicone or epoxy.

128. The electronic device of claim 123, further comprising one or more additional semiconductor dies suspended within the binder.

129. The electronic device of claim 123, wherein the binder contains a wavelength-conversion material therein.

130. The electronic device claim 129, wherein the wavelength material comprises at least one of a phosphor or quantum dots.

131. The electronic device of claim 123, wherein the semiconductor die comprises a light-emitting element.

132. The electronic device of claim 131, wherein the binder is transparent to a wavelength of light emitted by the light-emitting element.

133. The electronic device of claim 131, wherein the semiconductor die comprises a bare-die light-emitting diode.

134. The electronic device of claim 131, wherein the light-emitting element comprises a semiconductor material comprising at least one of GaAs, AlAs, InAs, GaP, AlP, InP, ZnO, CdSe, CdTe, ZnTe, GaN, AN, InN, silicon, or an alloy or mixture thereof.

135. The electronic device of claim 131, wherein the binder contains a wavelength-conversion material for absorption of at least a portion of light emitted from the light-emitting element and emission of converted light having a different wavelength, converted light and unconverted light emitted by the light-emitting element combining to form substantially white light.

136. The electronic device of claim 135, wherein the substantially white light has a correlated color temperature in the range of 2000 K to 10,000 K.

137. The electronic device of claim 123, wherein the binder has a thickness between 5 μ

m and 4000 μ

m.

138. The electronic device of claim 123, wherein a dimension of the binder perpendicular to the thickness is between 25 μ

m and 50 mm.

139. The electronic device of claim 123, wherein at least a portion of the surface of the binder comprises a texture for enhancing extraction of light from the binder.

140. The electronic device of claim 123, wherein the semiconductor die comprises a light-detecting element.

141. The electronic device of claim 140, wherein the binder is transparent to a wavelength of light detected by the light-detecting element.

142. The electronic device of claim 123, further comprising an optical element positioned to receive light from or transmit light to the semiconductor die.

143. The electronic device of claim 123, further comprising a reflecting layer over or within at least a portion of the binder.

144. The electronic device of claim 143, wherein the reflecting layer comprises at least one of (i) a reflecting film or (ii) a plurality of particles.

145. The electronic device of claim 143, wherein (a) the semiconductor die comprises a light-emitting element or a light-detecting element, and (b) the reflecting layer has a reflectivity of at least 25% to a wavelength of light (i) emitted or detected by the semiconductor die or (ii) emitted by the binder.

146. The electronic device of claim 123, wherein the binder comprises a plurality of discrete regions, at least one of which comprises the binder and at least one wavelength-conversion material.

147. The electronic device of claim 123, wherein the semiconductor die comprises one or more active semiconductor layers not disposed on a semiconductor substrate.

148. The electronic device of claim 123, further comprising one or more alignment marks on the surface of the binder for at least one of alignment or orientation of the semiconductor die.

149-218. -218. (canceled)