Illumination devices comprising white light emitting diodes and diode arrays and method and apparatus for making them
First Claim
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1. An illumination device comprising:
- a substrate having a surface and a cavity in the surface;
at least one light emitting diode (LED) mounted within the cavity;
a phosphor monolayer comprising phosphor particles overlying the LED, the phosphor particles for converting the emitted light into white light, the phosphor monolayer adhered to the LED by a monolayer of adhesive material.
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Abstract
In accordance with the invention, an illumination device comprises a substrate having a surface and a cavity in the surface. At least one light emitting diode (“LED”) is mounted within the cavity, and a monolayer comprising phosphor particles overlies the LED. The phosphor monolayer is adhered to the LED by a monolayer of transparent adhesive material. An optional optical thick layer of transparent material overlies the phosphor monolayer to encapsulate the LED and optionally to form a lens. Methods and apparatus for efficiently making the devices are disclosed.
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Citations
28 Claims
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1. An illumination device comprising:
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a substrate having a surface and a cavity in the surface; at least one light emitting diode (LED) mounted within the cavity; a phosphor monolayer comprising phosphor particles overlying the LED, the phosphor particles for converting the emitted light into white light, the phosphor monolayer adhered to the LED by a monolayer of adhesive material. - View Dependent Claims (2, 3, 4, 5, 6, 26)
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7. A method for making an illumination device comprising one or more white light LEDs comprising the steps of:
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providing a workpiece comprising a substrate having a surface including one or more cavities that contain one or more LEDs connected to electrical leads; forming a coating of tacky adhesive material overlying at least one of the LEDs; exposing the coating of tacky material to particles comprising phosphor material to form a self-limiting coating of particles overlying the at least one LED; and curing the tacky adhesive material. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 15, 16, 27, 28)
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17. Apparatus for coating phosphor particles on adhesive-coated LED workpieces comprising:
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an enclosed particle coating chamber for receiving the workpieces, a reservoir of phosphor particles to be coated, coupled to the chamber; a source of pressurized gas coupled to the chamber through a Venturi Nozzle; and a recycling chamber for receiving and recycling unused particles coupled to the chamber.
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18. An illumination device comprising:
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a substrate having a cavity; at least one light emitting diode (LED) mounted within the cavity; a self-limiting layer comprising phosphor particles adhered to the LED by a layer of adhesive material. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25)
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Specification