Illuminator and method for producing such illuminator

• US 8,541,797 B2
• Filed: 11/14/2005
• Issued: 09/24/2013
• Est. Priority Date: 11/18/2004
• Status: Active Grant

• Current Assignee: Lumileds LLC (Apollo Global Management, Inc.)
• Original Assignee: Koninklijke Philips N.V.
• Inventors: Hoelen, Christoph Gerard August, Van Den Ackerveken, Antonius Constant Johanna Cornelis, Rutjes, Cornelius Franciscus Jozef, Van Os, Koen, De Samber, Marc Andre, Treurniet, Theodoor Cornelis
• Primary Examiner(s): Maldonado, Julio J
• Assistant Examiner(s): CHOUDHRY, MOHAMMAD M
• Application Number:
  US11/719,240
• Publication Number:
  US 20090078948A1
• Time in Patent Office: 2,871 Days
• Field of Search: 438/69
• US Class Current: 257/98
• CPC Class Codes: H01L 2224/14 of a plurality of bump connectors
• CPC Class Codes: H01L 2224/16225 the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48227 connecting the wire to a bond pad of the item
• 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 33/60 Reflective elements

Abstract

An illuminator includes a substrate, a structured conductive layer applied to one surface of the substrate, and at least one light source connected to the structured conductive layer. The illuminator further includes an unstructured reflective layer applied on top of the structured conductive layer. The unstructured reflective layer has an essentially continuous extension at least in a surrounding of the at least one light source.

Claims

1. An illuminator having an exit surface and comprising:

a substrate;

a structured conductive layer applied on said substrate;

an isolating layer applied on said structured conductive layer;

at least one light source located on a first portion of the exit surface of the illuminator and connected to said structured conductive layer; and

a reflective layer applied on apart of the said isolating layer covering a second portion of the exit surface of the illuminator adjacent the at least one light source and surrounding said at least one light source, said reflective layer covering substantially all the exit surface of the illuminator not occupied by said at least one light source, wherein the reflective layer includes parts where the reflective layer is etched to accommodate the at least one light source, wherein the first portion of the exit surface is parallel to the second portion of the exit surface, and wherein the at least one light source protrudes from the reflective layer, wherein the exit surface is an outer surface of the illuminator for exit of light from the illuminator,

Wherein, the one light source is not in direct contact with the isolating layer and the reflective layer.

2. The illuminator according to claim 1, wherein said isolating layer comprises contact holes for enabling between the at least one light source and the structured conductive layer.

3. The illuminator according to claim 1, wherein said at least one light source is one of a flip chip light source and a wire bonded light source.

4. The illuminator according to claim 1, wherein said at least one light source is a light emitting diode.

7. The illuminator of claim 1, further comprising a dielectric layer between the isolation layer and the substrate.

5. A method for producing an illuminator having an exit surface, said method comprising the acts of:

providing a substrate;

applying a structured conductive layer on said substrate;

applying an isolating layer on said structured conductive layer;

applying a reflective layer on a part of the said isolating layer covering a portion of the exit surface of the illuminator;

etching parts of the reflective layer; and

placing at least one light source on the parts of the reflective layer that are etched for contacting the structured conductive layer,

wherein the reflective layer is on a first portion of the exit surface of the illuminator adjacent a second portion of the exit surface of the illuminator where the at least one light source is located, the reflective layer surrounding of the at least one light source, and wherein the reflective layer and the at least one light source cover substantially all the exit surface of the illuminator not occupied by any electrical connectors associated with the at least one light source,

wherein the first portion of the exit surface is parallel to the second portion of the exit surface and the at least one light source protrudes from the reflective layer, and wherein the exit surface is an outer surface of the illuminator for exit of light from the illuminator,

Wherein, the one light source is not in direct contact with the isolating layer and the reflective layer.

6. The method according to claim 5, further comprising the act of:

providing contact holes in the isolating layer for enabling connection the at least one light source and the structured conductive layer.

8. The method of claim 5, further comprising the act of forming a dielectric layer between the isolation layer and the substrate.