Method and apparatus for performing wavelength-conversion using phosphors with light emitting diodes

• US 6,404,125 B1
• Filed: 10/20/1999
• Issued: 06/11/2002
• Est. Priority Date: 10/21/1998
• Status: Expired due to Term

• Current Assignee: Emcore Corporation, Lightscape Materials, Inc.
• Original Assignee: Emcore Corporation, Sarnoff Corporation (SRI International, Inc.)
• Inventors: Connolly, John Charles, Garbuzov, Dmitri Zalmanovich, Ferguson, Ian Thomas, Karlicek, Robert Frank Jr.
• Primary Examiner(s): Patel, Vip
• Assistant Examiner(s): BERCK, KENNETH A
• Application Number:
  US09/421,584
• Time in Patent Office: 965 Days
• Field of Search: 313/498, 313/499, 313/501, 313/502, 313/503
• US Class Current: 313/499
• CPC Class Codes: H01L 27/156 two-dimensional arrays
• CPC Class Codes: H01L 33/10 with a light reflecting structure, e.g. semiconductor Bragg reflector
• CPC Class Codes: H01L 33/20 with a particular shape, e.g. curved or truncated substrate
• CPC Class Codes: H01L 33/46 Reflective coating, e.g. dielectric Bragg reflector
• CPC Class Codes: H01L 33/502 Wavelength conversion materials

Abstract

An apparatus comprises an active region, a phosphor layer and a substrate. The active region is configured to emit light having a first band of wavelengths selected from a first group of wavelengths. The phosphor layer has a first refractive index. The phosphor layer includes a plurality of wavelength-converting phosphors. The phosphor layer is configured to convert the first band of wavelengths of light emitted from the active region to a second band of wavelengths. A center wavelength of the second band of wavelengths is greater than a center wavelength of the first band of wavelengths. The substrate is disposed between and in contact with the active region and the phosphor layer. The substrate has a second refractive index. The first refractive index substantially equals the second refractive index.

Claims

1. An apparatus, comprising:

an active region, said active region configured to emit light having a first band of wavelengths selected from a first group of wavelengths;

a phosphor layer having a first refractive index, said phosphor layer including a plurality of wavelength-converting phosphors, said phosphor layer being configured to convert the first band of wavelengths of light emitted from said active region to a second band of wavelengths, a center wavelength of the second band of wavelengths being greater than a center wavelength of the first band of wavelengths; and

a substrate disposed between and in contact with said active region and said phosphor layer, said substrate having a second refractive index,

the first refractive index being substantially equal to the second refractive index.

2. The apparatus of claim 1, wherein the first group of wavelengths are between approximately 300 nm and approximately 500 nm.

3. The apparatus of claim 1, wherein:

said active region includes an active layer,

the first group of wavelengths are producible by the active layer constructed of at least Al_xGa_1-xN, x being between zero and one.

4. The apparatus of claim 1, wherein:

the first refractive index of said phosphor layer is substantially equal for the first band of wavelengths and at the second band of wavelengths.

5. The apparatus of claim 1, wherein:

said active region includes an active layer, a first device layer in contact with the active layer, a second device layer in contact with the active layer.

6. The apparatus of claim 1, wherein:

said active region includes an active layer, a first device layer in contact with the active layer, a second device layer in contact with the active layer,

the active layer is constructed of at least InGaN/Al_xGa_1-xN, x is a value between zero and one,

the first device layer is a p-type AlGaN layer in contact with the active layer, and

the second device layer is an n-type AlGaN layer disposed between and in contact with the active layer and said substrate.

7. An apparatus, comprising:

an active region having at an active layer and a first device layer, the first device layer having a first refractive index, said active region configured to emit light having a first band of wavelengths selected from a first group of wavelengths;

a phosphor layer having a second refractive index, said phosphor layer including a plurality of wavelength-converting phosphors, said phosphor layer being configured to convert the first band of wavelengths of light emitted from said active region to a second band of wavelengths, a center wavelength of the second band of wavelengths being greater than a center wavelength of the first band of wavelengths; and

the first device layer being disposed between and in contact with said active layer and said phosphor layer,

the first refractive index being substantially equal to the second refractive index.

8. The apparatus of claim 7, wherein the first group of wavelengths are between approximately 300 nm and approximately 500 nm.

9. The apparatus of claim 7, wherein:

the first group of wavelengths are producible by the active layer constructed of at least Al_xGa_1-xN, x being between zero and one.

10. The apparatus of claim 7, wherein:

the second refractive index of said phosphor layer is substantially equal for the first band of wavelengths and at the second band of wavelengths.

11. The apparatus of claim 7, wherein:

said active region includes a second device layer in contact with the active layer.

12. The apparatus of claim 7, wherein:

said active region includes a second device layer in contact with the active layer,

the active layer is constructed of at least InGaN/Al_xGa_1-xN, x is a value between zero and one,

the second device layer is a p-type AlGaN layer in contact with the active layer, and

the first device layer is an n-type AlGaN layer.

13. An apparatus, comprising:

an active region having at least an active layer and a first device layer, the first device layer having an active region refractive index, said active region configured to emit light having a first band of wavelengths from a first group of wavelengths; and

a phosphor layer being disposed between and in contact with said active region and an exterior medium, said phosphor layer being configured to convert the first band of wavelengths of light emitted from said active region to a second band of wavelengths, a center wavelength of the second band of wavelengths being greater than a center wavelength of the first band of wavelengths, said phosphor layer having a first refractive index associated with the first band of wavelengths and a second refractive index associated with the second band of wavelengths,

the first refractive index of said phosphor layer being substantially equal to the active region refractive index,

the second refractive index of said phosphor layer being substantially equal to a refractive index of the exterior medium.

14. The apparatus of claim 13, wherein the first group of wavelengths are between approximately 300 nm and approximately 500 nm.

15. The apparatus of claim 13, wherein:

the first group of wavelengths are producible by the active layer constructed of at least Al_xGa_1-xN, x is a value between zero and one.

16. The apparatus of claim 13, wherein:

said phosphor layer has a binder material and a plurality of wavelength-converting phosphors, a concentration of the plurality of wavelength-converting phosphors within said phosphor layer being high.

17. The apparatus of claim 13, wherein:

said active region includes a second device layer in contact with the active layer.

18. The apparatus of claim 13, wherein:

said active region includes a second device layer in contact with the active layer,

the active layer is constructed of at least InGaN/Al_xGa_1-xN, x is a value between zero and one,

the second device layer is a p-type AlGaN layer in contact with the active layer, and

the first device layer is an n-type AlGaN layer disposed between and in contact with the active layer and said phosphor layer.

19. An apparatus, comprising:

an active region, said active region configured to emit light having a first band of wavelengths from a first group of wavelengths;

a phosphor layer being disposed between and in contact with said active region and an exterior medium, said phosphor layer being configured to convert the first band of wavelengths of light emitted from said active region to a second band of wavelengths, a center wavelength of the second band of wavelengths being greater than a center wavelength of the first band of wavelengths, said phosphor layer having a first refractive index associated with the first band of wavelengths and a second refractive index associated with the second band of wavelengths, and

a substrate disposed between and in contact with said active region and said phosphor layer, said substrate having a third refractive index;

the first refractive index of said phosphor layer being substantially equal to the third refractive index,

the second refractive index of said phosphor layer being substantially equal to a refractive index of the exterior medium.

20. The apparatus of claim 19, wherein the first group of wavelengths are between approximately 300 nm and approximately 500 nm.

21. The apparatus of claim 19, wherein:

said active region includes an active layer;

the first group of wavelengths are producible by the active layer constructed of at least Al_xGa_1-xN, x is a value between zero and one.

22. The apparatus of claim 19, wherein:

said phosphor layer has a binder material and a plurality of wavelength-converting phosphors, a concentration of the plurality of wavelength-converting phosphors within said phosphor layer being high.

23. The apparatus of claim 19, wherein:

said active region includes an active layer, a first layer in contact with the active layer, and a second device layer in contact with the active layer.

24. The apparatus of claim 19, wherein:

said active region includes an active layer, a first device layer and a second device layer,

the active layer is constructed of at least InGaN/Al_xGa_1-xN, x is a value between zero and one,

the second device layer is a p-type AlGaN layer in contact with the active layer, and

the first device layer is an n-type AlGaN layer disposed between and in contact with the active layer and said substrate.

25. A method for designing a light-emitting device having an active region, a wavelength-converting phosphor layer and a substrate, the active region including at least an active layer and a first device layer, the substrate being disposed between and in contact with the first device layer and the wavelength-converting phosphor layer, said method comprising:

determining a phosphor concentration of the phosphor layer;

selecting, when the phosphor concentration of the phosphor layer is low, a refractive index of the substrate to be substantially equal to a refractive index of the phosphor layer; and

performing, when the phosphor concentration of the phosphor layer is high, the following;

selecting a refractive index of the phosphor layer at a first band of wavelengths to substantially equal a refractive index of the substrate, the first band of wavelengths being selected from a first group of wavelengths; and

selecting a refractive index of the phosphor layer at a second band of wavelengths to substantially equal a refractive index of an exterior medium adjacent to the phosphor layer,

the first band of wavelengths being associated with light emitted from the active region, the second band of wavelengths being associated with light wavelength-converted by the phosphor layer, a center wavelength of the second band of wavelengths being greater than a center wavelength of the first band of wavelengths.

26. The apparatus of claim 25, wherein the first group of wavelengths are between approximately 300 nm and approximately 500 nm.

27. The apparatus of claim 25, wherein:

the first group of wavelengths are producible by the active layer constructed of at least Al_xGa_1-xN, x is a value between zero and one.

28. The apparatus of claim 25, wherein:

said active region includes a second device layer in contact with the active layer.

29. The apparatus of claim 25, wherein:

said active region includes a second device layer in contact with the active layer,

the active layer is constructed of at least InGaN/Al_xGa_1-xN, x is a value between zero and one,

the second device layer is a p-type AlGaN layer in contact with the active layer, and

the first device layer is an n-type AlGaN layer disposed between and in contact with the active layer and said substrate.

30. A method for designing a light-emitting device having an active region and a wavelength-converting phosphor layer, the active region including at least an active layer and a first device layer, the first device layer being disposed between and in contact with the active layer and the wavelength-converting phosphor layer, said method comprising:

determining a phosphor concentration of the phosphor layer;

selecting, when the phosphor concentration of the phosphor layer is low, a refractive index of the first device layer to be substantially equal to a refractive index of the phosphor layer; and

performing, when the phosphor concentration of the phosphor layer is high, the following;

selecting a refractive index of the phosphor layer at a first band of wavelengths to substantially equal a refractive index of the first device layer, the first band of wavelengths being selected from a first group of wavelengths; and

selecting a refractive index of the phosphor layer at a second band of wavelengths to substantially equal a refractive index of an exterior medium adjacent to the phosphor layer,

the first band of wavelengths being associated with light emitted from the active region, the second band of wavelengths being associated with light wavelength-converted by the phosphor layer, a center wavelength of the second band of wavelengths being greater than a center wavelength of the first band of wavelengths.

31. The apparatus of claim 30, wherein the first group of wavelengths are between approximately 300 nm and approximately 500 nm.

32. The apparatus of claim 30, wherein:

the first group of wavelengths are producible by the active layer constructed of at least Al_xGa_1-xN, x is a value between zero and one.

33. The apparatus of claim 30, wherein:

said active region includes a second device layer in contact with the active layer.

34. The apparatus of claim 30, wherein:

said active region includes a second device layer in contact with the active layer,

the active layer is constructed of at least InGaN/Al_xGa_1-xN, x is a value between zero and one,

the second device layer is a p-type AlGaN layer in contact with the active layer, and

the first device layer is an n-type AlGaN layer disposed between and in contact with the active layer and the phosphor layer.