LED with phosphor tile and overmolded phosphor in lens
First Claim
1. A process for forming a light emitting diode (LED) structure comprising:
- providing an LED emitting blue light on a submount;
affixing a substantially flat preformed phosphor plate to the LED, the preformed phosphor plate containing YAG phosphor emitting a yellow light, wherein a combination of blue light from the LED leaking through the phosphor plate and the yellow light produces white light;
providing a mold having an indention corresponding to an intermediate lens;
filling the indention with a liquid lens material containing a phosphor that generates at least red light when excited by the blue light leaking through the phosphor plate;
after the step of filling, immersing at least the phosphor plate and a portion of the LED into the liquid lens material in the mold; and
curing the liquid lens material to form a phosphor-loaded lens over the phosphor plate and LED.
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Accused Products
Abstract
Overmolded lenses and certain fabrication techniques are described for LED structures. In one embodiment, thin YAG phosphor plates are formed and affixed over blue LEDs mounted on a submount wafer. A clear lens is then molded over each LED structure during a single molding process. The LEDs are then separated from the wafer. The molded lens may include red phosphor to generate a warmer white light. In another embodiment, the phosphor plates are first temporarily mounted on a backplate, and a lens containing a red phosphor is molded over the phosphor plates. The plates with overmolded lenses are removed from the backplate and affixed to the top of an energizing LED. A clear lens is then molded over each LED structure. The shape of the molded phosphor-loaded lenses may be designed to improve the color vs. angle uniformity. Multiple dies may be encapsulated by a single lens. In another embodiment, a prefabricated collimating lens is glued to the flat top of an overmolded lens.
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Citations
11 Claims
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1. A process for forming a light emitting diode (LED) structure comprising:
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providing an LED emitting blue light on a submount; affixing a substantially flat preformed phosphor plate to the LED, the preformed phosphor plate containing YAG phosphor emitting a yellow light, wherein a combination of blue light from the LED leaking through the phosphor plate and the yellow light produces white light; providing a mold having an indention corresponding to an intermediate lens; filling the indention with a liquid lens material containing a phosphor that generates at least red light when excited by the blue light leaking through the phosphor plate; after the step of filling, immersing at least the phosphor plate and a portion of the LED into the liquid lens material in the mold; and curing the liquid lens material to form a phosphor-loaded lens over the phosphor plate and LED. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A process for forming a light emitting diode (LED) structure comprising:
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providing an LED emitting blue light or UV light on a submount; molding a first phosphor phosphor-loaded lens containing a first phosphor over the LED; molding a second phosphor-loaded lens over the first phosphor-loaded lens, the second phosphor-loaded lens containing a second phosphor different from the first phosphor; and determining a color temperature vs. viewing angle of the LED with the first phosphor-loaded lens, and then molding the second phosphor-loaded lens to increase uniformity of the color temperature vs. viewing angle.
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8. A process for forming a light emitting diode (LED) structure comprising:
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providing an LED on a submount; providing a first mold having a first indention with a shape corresponding to a first lens; filling the first indention with a first liquid lens material; after the step of filling, immersing the LED into the first liquid lens material in the first mold; curing the first liquid lens material to form the first lens over the LED; removing the LED with the first lens from the first mold; plasma treating the first lens; providing a second mold having a second indention with a shape corresponding to a second lens; filling the second indention with a second liquid lens material; after the step of filling the second indentation, immersing the LED and first lens into the second liquid lens material in the second mold; curing the second liquid lens material to form the second lens over the LED, wherein the step of plasma treating increases adherence of the first lens to the second lens; and removing the LED with the first lens and second lens from the second mold. - View Dependent Claims (9, 10, 11)
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Specification