System and method for emitter layer shaping
First Claim
1. A method of shaping an emitter layer of the LED, comprising:
- determining an exit area (b) and an emitter area (a) of a miniature emitter, wherein the exit area (b) has an exit face in a first geometric configuration and wherein the emitter area (a) has a quantum well region in a second geometric configuration;
determining a minimum height (h) of the miniature emitter utilizing the exit area (b) and the emitter area (a);
removing matter from an emitting material or growing the emitting material according to the first geometric configuration, the second geometric configuration, and the minimum height (h) to form a shaped portion having one or more miniature emitters meeting the minimum height (h); and
shaping sidewalls of the miniature emitters, wherein each sidewall is positioned and shaped to cause at least a majority of rays having a straight transmission path from the emitter area to that sidewall to reflect to the exit face with an angle of incidence at the exit face at less than or equal to a critical angle at the exit face.
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Accused Products
Abstract
Embodiments of an LED disclosed has an emitter layer shaped to a controlled depth or height relative to a substrate of the LED to maximize the light output of the LED and to achieve a desired intensity distribution. In some embodiments, the exit face of the LED may be selected to conserve radiance. In some embodiments, shaping the entire LED, including the substrate and sidewalls, or shaping the substrate alone can extract 100% or approximately 100% of the light generated at the emitter layers from the emitter layers. In some embodiments, the total efficiency is at least 90% or above. In some embodiments, the emitter layer can be shaped by etching, mechanical shaping, or a combination of various shaping methods. In some embodiments, only a portion of the emitter layer is shaped to form the tiny emitters. The unshaped portion forms a continuous electrical connection for the LED.
525 Citations
18 Claims
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1. A method of shaping an emitter layer of the LED, comprising:
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determining an exit area (b) and an emitter area (a) of a miniature emitter, wherein the exit area (b) has an exit face in a first geometric configuration and wherein the emitter area (a) has a quantum well region in a second geometric configuration; determining a minimum height (h) of the miniature emitter utilizing the exit area (b) and the emitter area (a); removing matter from an emitting material or growing the emitting material according to the first geometric configuration, the second geometric configuration, and the minimum height (h) to form a shaped portion having one or more miniature emitters meeting the minimum height (h); and shaping sidewalls of the miniature emitters, wherein each sidewall is positioned and shaped to cause at least a majority of rays having a straight transmission path from the emitter area to that sidewall to reflect to the exit face with an angle of incidence at the exit face at less than or equal to a critical angle at the exit face. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An LED manufactured by a method of shaping an emitter layer of the LED, the method comprising:
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determining an exit area (b) and an emitter area (a) of a miniature emitter, wherein the exit area (b) has an exit face in a first geometric configuration and wherein the emitter area (a) has a quantum well region in a second geometric configuration; determining a minimum height (h) of the miniature emitter utilizing the exit area (b) and the emitter area (a); removing matter from an emitting material or growing the emitting material according to the first geometric configuration, the second geometric configuration, and the minimum height (h) to form a shaped portion having one or more miniature emitters meeting the minimum height (h); and shaping sidewalls of the miniature emitters, wherein each sidewall is positioned and shaped to cause at least a majority of rays having a straight transmission path from the emitter area to that sidewall to reflect to the exit face with an angle of incidence at the exit face at less than or equal to a critical angle at the exit face. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18)
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Specification