Phosphor based light source component and method of making

• US 7,210,977 B2
• Filed: 12/02/2003
• Issued: 05/01/2007
• Est. Priority Date: 01/27/2003
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Wheatley, John A., Ouderkirk, Andrew J.
• Primary Examiner(s): Guharay; Karabi
• Assistant Examiner(s): Roy; Sikha
• Application Number:
  US10/726,790
• Publication Number:
  US 20040145288A1
• Time in Patent Office: 1,246 Days
• Field of Search: 313/512
• US Class Current: 445/24
• CPC Class Codes: H01J 1/70 with protective, conductive, or reflective layers
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/12041 LED
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 33/44 characterised by the coatings, e.g. passivation layer or anti-reflective coating
• CPC Class Codes: H01L 33/507 the elements being in intimate contact with parts other than the semiconductor body or integrated with parts other than the semiconductor body

Abstract

A method of making a light source includes the steps of forming a first optical component having a phosphor material in fixed relation to a first multilayer interference reflector, providing a second optical component having an LED capable of emitting light that excites the phosphor material, and positioning the first optical component to receive emitted light from the second optical component.

Claims

1. A method of making a light source, comprising the steps of:

forming a first optical component comprising a phosphor material in fixed relation to a first multilayer interference reflector;

providing a second optical component comprising an LED capable of emitting light that excites the phosphor material; and

positioning the first optical component to receive emitted light from the second optical component;

wherein the positioning step is performed after the forming and providing steps.

2. The method according to claim 1, wherein the first multilayer interference reflector is a first flexible multilayer interference reflector.

3. The method according to claim 1, wherein the first multilayer interference reflector is a first polymeric multilayer interference reflector.

4. The method according to claim 1, wherein the forming step comprises dispersing phosphor particles in an adhesive material.

5. The method according to claim 1, wherein the first multilayer interference reflector includes alternating layers of a first and second thermoplastic polymer, and wherein at least some of the layers are birefringent.

6. The method according to claim 1, wherein the forming step comprises laminating the phosphor material to the first multilayer interference reflector to form a phosphor-reflector assembly.

7. The method according to claim 1, wherein the forming step comprises coating the phosphor material on the first multilayer interference reflector to form a phosphor-reflector assembly.

8. The method according to claim 1, wherein the forming step further comprises disposing a second multilayer interference reflector in fixed relation to the phosphor material.

9. The method according to claim 1, wherein the forming step comprises embedding the phosphor material and the first multilayer interference reflector in an optically transparent potting material.

10. The method according to claim 1, wherein the first multilayer interference reflector is a first polymeric multilayer short-pass or long-pass reflector.

11. The method according to claim 10, wherein the forming step comprises forming the phosphor material in fixed relation to a second polymeric multilayer short-pass or long-pass reflector.

12. The method according to claim 1, wherein the forming step comprises forming a first polymeric multilayer long-pass reflector, and a sceond polymeric multilayer short-pass reflector.

13. The method according to claim 1, wherein the forming step comprises forming a layer of the phosphor material.

14. The method according to claim 1, wherein the forming step comprises forming a discontinuous layer of the phosphor material.

15. The method according to claim 14, wherein the discontinuous layer defines a plurality of dots.

16. The method according to claim 15, wherein each dot has an area of less than 10000 microns².

17. The method according to claim 1, wherein the positioning step comprises joining the first optical component to the second optical component.

18. The method according to claim 1, wherein the first and second optical components have surfaces configured to mate with each other, the positioning step comprising mating the first optical component with the second optical component along such mating surfaces.