Low stress light-emitting diode mounting package
First Claim
1. A light-emitting diode package comprising:
- a metal lead;
a cavity having walls, a bottom and an open end in the metal lead;
a light-emitting diode having sides and a front face in the bottom of the cavity in electrical contact with the metal lead; and
a rigid plastic potting material between the light-emitting diode and the walls of the cavity, andmeans for minimizing light degradation of the light-emitting diode comprising a sufficiently small clearance between the sides of the light-emitting diode and the walls of the cavity that the amount of plastic potting material between the sides of the light-emitting diode and the walls is insufficient for applying light degrading stresses on the light-emitting diode due to differential thermal expansion.
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Accused Products
Abstract
A light-emitting diode is mounted in the bottom of a cavity in a metal lead and the assembly is potted in a transparent plastic material. The walls of the cavity surround the sides of the light-emitting diode in sufficiently close proximity to effectively shield the light-emitting diode from thermal expansion stresses from the plastic potting material which would induce light output degradation. Such a cavity may be a right-circular cylinder with a diameter less than 75 micrometers greater than the largest transverse dimension of the light-emitting diode. The front face of the light-emitting diode may be flush or beneath the face of the metal lead for minimizing stress. The cavity may be deep enough that the front face of the light-emitting diode is closer to the bottom of the cavity than to its open end. The front face may protrude beyond the open end of the cavity and be surrounded by a reflective surface. The edges of the front face of the light-emitting diode may be beveled for minimizing stress.
63 Citations
30 Claims
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1. A light-emitting diode package comprising:
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a metal lead; a cavity having walls, a bottom and an open end in the metal lead; a light-emitting diode having sides and a front face in the bottom of the cavity in electrical contact with the metal lead; and a rigid plastic potting material between the light-emitting diode and the walls of the cavity, and means for minimizing light degradation of the light-emitting diode comprising a sufficiently small clearance between the sides of the light-emitting diode and the walls of the cavity that the amount of plastic potting material between the sides of the light-emitting diode and the walls is insufficient for applying light degrading stresses on the light-emitting diode due to differential thermal expansion. - View Dependent Claims (4, 7)
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2. A light-emitting diode package comprising:
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a metal lead; a cavity having walls, a bottom and an open end in the metal lead; a light-emitting diode having a sides and a front face in the bottom of the cavity in electrical contact with the metal lead, a side wall of the cavity adjacent to at least the bottom of the cavity being substantially parallel to the side faces of the light-emitting diode; and a plastic potting material between the light-emitting diode and the walls of the cavity, the amount of plastic potting material being insufficient to apply light degrading stresses on the light-emitting diode due to differential thermal expansion. - View Dependent Claims (3, 6, 10)
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5. A light-emitting diode package comprising:
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a metal lead; a cavity having walls, a bottom and a open end in the metal lead; a light-emitting diode having sides and a front face in the bottom of the cavity in electrical contact with the metal lead; wherein the cavity is round and the diameter of the cavity is less than 75 micrometers greater than the largest transverse dimension of the light-emitting diode; and a plastic potting material between the light-emitting diode and the walls of the cavity, the amount of plastic potting material being insufficient to apply light degrading stresses on the light-emitting diode due to differential thermal expansion.
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8. A light-emitting diode package comprising:
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a metal lead; a cavity having walls a bottom and a open end in the metal lead; a light-emitting diode having sides and a front face in the bottom of the cavity in electrical contact with the metal lead; and a rigid plastic potting material outside the cavity and between the light-emitting diode and the walls of the cavity; and means for shielding the light-emitting diode from light degrading differential thermal expansion stresses from potting material outside the cavity comprising a sufficiently deep cavity that the front face of the light-emitting diode is a sufficient distance below the face of the lead adjacent to the cavity that stresses from plastic potting material outside the cavity are not effectively coupled into the cavity to the depth of the front face of the light-emitting diode. - View Dependent Claims (9)
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11. A light-emitting diode package comprising:
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a metal lead; a cavity having walls, a bottom and an open end; a light-emitting diode having sides and a front face mounted on the metal lead; a transparent plastic potting material surrounding the lead and light-emitting diode; and means for effectively shielding the light-emitting diode front thermal expansion stresses applied by the plastic potting material on the light-emitting diode comprising a cavity in the lead having a wall surrounding the sides of the light-emitting diode in sufficiently close proximity to the sides of the light-emitting diode for effectively shielding the light-emitting diode from thermal expansion stresses applied by the plastic potting material on the light-emitting diode. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18)
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19. A light-emitting diode package comprising:
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a metal lead; a light-emitting diode having sides and a front face mounted on the metal lead; a rigid transparent plastic potting material surrounding the lead and light-emitting diode; a cavity have walls, a bottom and an open end in the lead; and means for effectively shielding the light-emitting diode from thermal expansion stresses exerted by the plastic potting material outside of the cavity comprising a cavity wall extending a sufficient distance beyond the front face of the light-emitting diode for effectively shielding the light-emitting diode from thermal expansion stresses exerted by the plastic potting material outside of the cavity. - View Dependent Claims (20, 21, 22)
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23. A light emitting diode package comprising:
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a metal lead; a substantially cylindrical cavity having walls, a bottom and an open end in the metal lead; a light-emitting diode having sides and a front face in the bottom of the cylindrical cavity in electrical contact with the metal lead, at least a major portion of the light-emitting diode being below the open end of the cavity; and a layer of rigid transparent plastic potting material surrounding the lead and between the wall of the cylindrical cavity and the sides of the light-emitting diode, the amount of plastic potting material being insufficient to apply light degrading stresses on the light-emitting diode due to differential thermal expansion. - View Dependent Claims (24, 25, 26, 27, 28, 29)
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30. A light-emitting diode package comprising:
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a metal lead; a cavity having walls, a bottom and an open end in the metal lead; a light-emitting diode having sides in the bottom of the cavity in electrical contact with the metal lead, at least a major portion of the light-emitting diode being below the open end of the cavity; and a transparent plastic potting material surrounding the light-emitting diode in the cavity; and
whereinthe walls of the cavity are within no more than 75 micrometers of the sides of the light-emitting diode.
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Specification