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Phosphor position in light emitting diodes

  • US 8,425,271 B2
  • Filed: 08/16/2007
  • Issued: 04/23/2013
  • Est. Priority Date: 09/01/2006
  • Status: Active Grant
First Claim
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1. A method of forming an LED lamp with a desired distribution of phosphor, the method comprising:

  • selecting a desired position of phosphor particles with respect to an LED chip;

    selecting a particle size of a plurality of phosphor particles based on a viscosity of an uncured polymer resin in response to temperature changes and based on said desired position of the phosphor particles with respect to the LED chip;

    mixing a plurality of phosphor particles in the uncured polymer resin for which the viscosity can be controlled in response to temperature to form a substantially uniform suspension of the phosphor particles in the resin;

    placing the uncured resin into a defined position adjacent the LED chip;

    increasing the temperature of the resin in a first step to a temperature that correspondingly decreases the viscosity of the resin without immediately curing the resin;

    encouraging the phosphor particles to settle in the lowered-viscosity resin to the desired position with respect to the LED chip; and

    in response to the phosphor particles having settled at the desired position, thereafter increasing the temperature of the substantially uncured resin in a second step to a temperature higher than the first step and at which it will cure and solidify in about two hours or less.

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