Light emitting diode package element with internal meniscus for bubble free lens placement
First Claim
1. A light emitting diode (LED) package, comprising:
- a substrate with an LED chip mounted to it;
a meniscus forming feature on said substrate around said LED chip, said meniscus forming feature comprising an edge defined by the intersection of an upper surface of said meniscus forming feature opposite said substrate and a side surface of said meniscus forming feature facing away from said LED chip;
an inner encapsulant over said LED chip and having a contacting surface on said substrate, said meniscus forming feature defining the edge of said contacting surface;
an optical element having a bottom surface with at least a portion that is concave, said optical element on said substrate with said concave portion over said LED chip; and
a contacting encapsulant between said inner encapsulant and said optical element.
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Accused Products
Abstract
A method for fabricating a light emitting diode (LED) package comprising providing an LED chip and covering at least part of the LED chip with a liquid encapsulant having a radius of curvature. An optical element is provided having a bottom surface with at least a portion having a radius of curvature larger than the liquid encapsulant. The larger radius of curvature portion of the optical element is brought into contact with the liquid encapsulant. The optical element is then moved closer to the LED chip, growing the contact area between said optical element and said liquid encapsulant. The liquid encapsulant is then cured. A light emitting diode comprising a substrate with an LED chip mounted to it. A meniscus ring is on the substrate around the LED chip with the meniscus ring having a meniscus holding feature. An inner encapsulant is provided over the LED chip with the inner encapsulant having a contacting surface on the substrate, with the meniscus holding feature which defines the edge of the contacting surface. An optical element is included having a bottom surface with at least a portion that is concave. The optical element is arranged on the substrate with the concave portion over the LED chip. A contacting encapsulant is included between the inner encapsulant and optical element.
70 Citations
21 Claims
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1. A light emitting diode (LED) package, comprising:
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a substrate with an LED chip mounted to it; a meniscus forming feature on said substrate around said LED chip, said meniscus forming feature comprising an edge defined by the intersection of an upper surface of said meniscus forming feature opposite said substrate and a side surface of said meniscus forming feature facing away from said LED chip; an inner encapsulant over said LED chip and having a contacting surface on said substrate, said meniscus forming feature defining the edge of said contacting surface; an optical element having a bottom surface with at least a portion that is concave, said optical element on said substrate with said concave portion over said LED chip; and a contacting encapsulant between said inner encapsulant and said optical element. - View Dependent Claims (2, 3, 4, 5, 6, 21)
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7. A light emitting diode (LED) package, comprising:
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an LED chip; a meniscus forming feature disposed around said LED chip, said meniscus forming feature comprising an edge defined by the intersection of an upper surface of said meniscus forming feature and a side surface of said meniscus forming feature facing away from said LED chip; an encapsulant over said LED chip; and an optical element with a bottom surface, said bottom surface having at least a portion with a radius of curvature larger than a radius of curvature of said encapsulant prior to curing, said bottom surface arranged to conformally contact an exposed surface of said encapsulant such that substantially no air is trapped between the two. - View Dependent Claims (8, 9, 10, 11, 12, 13)
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14. A light emitting diode (LED) array package, comprising:
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a substrate with a plurality of LED chips; an inner encapsulant over each of said LED chips, said inner encapsulant having a contacting surface on said substrate; a meniscus forming feature on said substrate around each of said LED chips, said meniscus forming feature comprising an edge defined by the intersection of an upper surface of said meniscus forming feature opposite said substrate and a side surface of said meniscus forming feature facing away from said LED chip; an optical element over each of said LED chips, each optical element having a bottom surface with at least a portion that is concave, with said concave portion over said LED chip; and a contacting encapsulant between each said inner encapsulant and said optical element associated therewith. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification