Light emitting diode source with protective barrier

• US 8,084,777 B2
• Filed: 03/24/2009
• Issued: 12/27/2011
• Est. Priority Date: 03/24/2009
• Status: Active Grant

• Current Assignee: Bridgelux Incorporated
• Original Assignee: Bridgelux Incorporated
• Inventors: Posselt, Jason
• Primary Examiner(s): Sandvik, Benjamin
• Assistant Examiner(s): KHAN, FARID H
• Application Number:
  US12/410,208
• Publication Number:
  US 20100142180A1
• Time in Patent Office: 1,008 Days
• Field of Search: 257/79, 257/99, 257/81, 257/98, 257/100, 257/433, 257/684, 257/687, 257/709, 257/E21.499, 257/E23.002, 257/E23.003, 257/E23.004, 257/E23.007, 257/E23.008, 257/E33.058, 257/E33.059, 257/E33.061, 257/E33.072, 438/26, 438/25, 438/29, 438/64, 438/126
• US Class Current: 257/99
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21S 41/151 arranged in one or more lines
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: F21W 2131/10 Outdoor lighting
• CPC Class Codes: F21W 2131/305 for refrigerators
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48137 the bodies being arranged next to each other, e.g. on a common substrate
• 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 2924/181 Encapsulation
• CPC Class Codes: H05K 2201/10106 Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10189 Non-printed connector
• CPC Class Codes: H05K 2201/2018 Presence of a frame in a printed circuit or printed circuit assembly
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence

Abstract

An apparatus having a substrate, an LED light source attached to the substrate, an electrical connector attached to the substrate and electrically connected to the LED light source, a potting material on the substrate and covering at least a portion of the electrical connector; and a barrier separating the potting material from the LED light source, the barrier having a height that exceeds the thickness of the potting material on the substrate.

Claims

1. An apparatus, comprising:

a substrate having a top surface;

a LED light source attached to the top surface of the substrate;

at least one electrical connector attached to the substrate and electrically connected to the LED light Source;

a potting material disposed on the top surface of the substrate and covering at least a portion of the electrical connector, and metallic traces on the substrate;

an encapsulation material on the top surface of the substrate and covering at least a portion of the LED light source but not on any part of the potting material; and

a barrier on the top surface of the substrate separating the potting material from the LED light source, the barrier having a height that exceeds the maximum thickness of the entire potting material on the substrate, the barrier further separating the potting material and the encapsulation material.

2. The apparatus of claim 1 wherein the LED light source comprises an LED array.

3. The apparatus of claim 1 wherein the LED light source comprises at least one LED encapsulated with the encapsulation material.

4. The apparatus of claim 3 wherein the height of the barrier exceeds the maximum thickness of the encapsulation material, and wherein the space between the barriers is entirely covered by the encapsulation material, and wherein no other encapsulating or covering materials are disposed over said encapsulation material.

5. The apparatus of claim 3 wherein each of said at least one LED comprises a blue LED and the encapsulation material includes phosphor.

6. The apparatus of claim 1 wherein the barrier comprises a rim that extends away from the encapsulation material and outwards towards the potting material and extends over at least a part of the potting material.

7. The apparatus of claim 1 wherein the barrier includes a reflective surface arranged to reflect light emitted from the LED light source.

21. The apparatus of claim 1, wherein the barrier is formed directly on the substrate.

22. The apparatus of claim 1, wherein the barrier is formed separately from the substrate.

8. An apparatus, comprising:

a substrate having a top surface;

an LED light source attached to the top surface of the substrate;

a barrier surrounding at least at least a portion of the light source on the top surface of the substrate;

at least one electrical connector attached to the substrate and electrically connected to the LED light source;

the electrical connector being on the opposite side of the barrier from the LED light source;

a potting material disposed on the top surface of the substrate and covering at least a portion of the electrical connector, and metallic traces on the substrate;

an encapsulation material disposed on the top surface of the substrate and covering at least a portion of the LED light source; and

wherein the barrier has a height that exceeds the maximum thickness of the entire potting material on the substrate; and

wherein the barrier completely separates the potting material and the encapsulation material.

9. The apparatus of claim 8 wherein the LED light source comprises an LED array.

10. The apparatus of claim 8 wherein the LED light source comprises at least one LED encapsulated with the encapsulation material.

11. The apparatus of claim 10 wherein the height of the barrier exceeds the maximum thickness of the encapsulation material, and wherein the space between the barriers is entirely covered by the encapsulation material, and wherein no other encapsulating or covering materials are disposed over said encapsulation material.

12. The apparatus of claim 10 wherein each of said at least one LED comprises a blue LED and the encapsulation material includes phosphor.

13. The apparatus of claim 8 wherein the barrier comprises a rim that extends away from the encapsulation material and outwards towards the potting material and extends over at least a part of the potting material.

14. The apparatus of claim 8 wherein the barrier includes a reflective surface arranged to reflect light emitted from the LED light source.

15. An apparatus, comprising:

a substrate having a top surface;

an LED light source attached to the top surface of the substrate;

at least one electrical connector attached to the substrate and electrically connected to the LED light source;

a potting material disposed on the top surface of the substrate and covering at least a portion of the electrical connector, and metallic traces on the substrate;

an encapsulation material disposed on the top surface of the substrate and covering at least a portion of the LED light source; and

a barrier between the LED light source and the electrical connector, the barrier having a height that exceeds the maximum thickness of the entire potting material on the substrate, and wherein the barrier separates the potting material and the encapsulation material.

16. The apparatus of claim 15 wherein the LED light source comprises an LED array.

17. The apparatus of claim 15 wherein the LED light source comprises at least one LED encapsulated in the encapsulation material.

18. The apparatus of claim 17 wherein the height of the barrier exceeds the maximum thickness of the encapsulation material, and wherein the space between the barriers is entirely covered by the encapsulation material, and wherein no other encapsulating or covering materials are disposed over said encapsulation material.

19. The apparatus of claim 17 wherein each of said at least one LED comprises a blue LED and the encapsulation material includes phosphor.

20. The apparatus of claim 15 wherein the barrier includes a reflective surface arranged to reflect light emitted from the LED light source.