Solid state lighting device with reduced form factor including LED with directional emission and package with microoptics
First Claim
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1. A method of making a packaged light emitting diode, comprising:
- forming a first conductivity type semiconductor contact layer on a transparent substrate;
forming a semiconductor active layer over a first surface of the first conductivity type semiconductor contact layer;
forming a second conductivity type semiconductor contact layer over the active layer;
patterning the first conductivity type semiconductor layer, the second conductivity type semiconductor contact layer and the active layer;
forming a first metal containing electrode contacting the first conductivity type semiconductor contact layer;
forming a second metal containing electrode contacting the second conductivity type semiconductor contact layer to yield a light emitting diode; and
forming a packaged light emitting diode containing at least one integrated microoptical element above the light emitting diode, wherein forming the packaged light emitting diode comprises;
mounting the light emitting diode in a flip chip configuration on a package, wherein the first electrode electrically contacts a first lead on the package, the second electrode electrically contacts a second lead on the package and the substrate is positioned toward a light emitting surface of the package;
forming a transparent encapsulating material layer over the transparent substrate, through which light from the light emitting diode passes;
forming a flexible sheet over the encapsulating material layer; and
etching the at least one microoptical element on the flexible sheet, through which light from the light emitting diode passes after passage through the encapsulating material layer.
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Abstract
A light emitting device containing an array of directional emission LEDs is provided. The directional emission LEDs of the array may be substrate emitting, lateral current injection, resonant cavity LEDs mounted in a flip-chip configuration. Each LED may emit a different color of light, such that the output of the array appears white to an observer. The LED array package may contain microoptical elements, such as a diffraction grating or microprisms, integrated into the light emitting surface of the package. The microoptical elements are used to mix the light beams emitted by individual LEDs in the array.
87 Citations
13 Claims
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1. A method of making a packaged light emitting diode, comprising:
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forming a first conductivity type semiconductor contact layer on a transparent substrate; forming a semiconductor active layer over a first surface of the first conductivity type semiconductor contact layer; forming a second conductivity type semiconductor contact layer over the active layer; patterning the first conductivity type semiconductor layer, the second conductivity type semiconductor contact layer and the active layer; forming a first metal containing electrode contacting the first conductivity type semiconductor contact layer; forming a second metal containing electrode contacting the second conductivity type semiconductor contact layer to yield a light emitting diode; and forming a packaged light emitting diode containing at least one integrated microoptical element above the light emitting diode, wherein forming the packaged light emitting diode comprises; mounting the light emitting diode in a flip chip configuration on a package, wherein the first electrode electrically contacts a first lead on the package, the second electrode electrically contacts a second lead on the package and the substrate is positioned toward a light emitting surface of the package; forming a transparent encapsulating material layer over the transparent substrate, through which light from the light emitting diode passes; forming a flexible sheet over the encapsulating material layer; and etching the at least one microoptical element on the flexible sheet, through which light from the light emitting diode passes after passage through the encapsulating material layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of packaging a light emitting diode (LED), comprising:
mounting the LED on a package in a flip chip configuration, wherein; a first electrode of the LED electrically contacts a first lead of the package; a second electrode of the LED electrically contacts a second lead of the package; a transparent substrate of the LED is positioned toward a light emitting surface; forming a transparent encapsulating material layer over the transparent substrate, through which light from the light emitting diode passes; forming a flexible sheet over the encapsulating material layer; and etching the at least one microoptical element on the flexible sheet, through which light from the light emitting diode passes after passage through the encapsulating material layer.
Specification