Complex primary optics with intermediate elements

• US 8,564,004 B2
• Filed: 11/29/2011
• Issued: 10/22/2013
• Est. Priority Date: 11/29/2011
• Status: Active Grant

• Current Assignee: Creeled Incorporated
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Tarsa, Eric, Keller, Bernd, Guschl, Peter, Negley, Gerald
• Primary Examiner(s): LE, DUNG ANH
• Application Number:
  US13/306,589
• Publication Number:
  US 20130134445A1
• Time in Patent Office: 693 Days
• Field of Search: 257/79, 257/82, 257 98-100, 257432-434, 257/672
• US Class Current: 257/98
• CPC Class Codes: B29C 33/52 soluble or fusible in particular used in injection moulding B29C45/4457
• CPC Class Codes: B29C 33/68 Release sheets
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 45/14655 connected to or mounted on a carrier, e.g. lead frame
• CPC Class Codes: B29C 45/4457 using fusible, soluble or destructible cores
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G02B 19/0028 refractive and reflective surfaces, e.g. non-imaging catadioptric systems
• CPC Class Codes: G02B 19/0061 the light source comprising a LED semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission H01L33/00
• CPC Class Codes: G02B 19/0066 in the form of an LED array
• CPC Class Codes: H01L 2224/48091 Arched
• 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 2933/005 relating to encapsulations
• CPC Class Codes: H01L 33/54 having a particular shape
• CPC Class Codes: H01L 33/58 Optical field-shaping elements

Abstract

A light emitter package comprising a light emitter disposed on a surface and a primary optic comprising an encapsulant disposed over the light emitter is disclosed. The package further comprises at least one intermediate element on the surface and at least partially surrounding the light emitter such that the intermediate element at least partially defines the shape of the primary optic. The intermediate element is configured so at least a portion of the intermediate element can be removed.

Claims

1. A light emitter package, comprising:

a light emitter disposed on a surface;

at least one intermediate element on said surface at least partially surrounding said light emitter, each of said intermediate elements configured such that at least a portion of said intermediate element can be removed; and

an encapsulant over said light emitter forming a primary optic, said at least one intermediate element at least partially defining the shape of said primary optic.

2. The light emitter package of claim 1, wherein said primary optic is capable of beam shaping.

3. The light emitter package of claim 1, wherein said light emitter comprises an LED.

4. The light emitter package of claim 1, wherein said intermediate element includes a meniscus forming feature.

5. The light emitter package of claim 1, wherein said primary optic comprises an exit face and has a tapered shape such that at least a portion closer to the base of said primary optic is narrower than at least a portion of the exit face.

6. The light emitter package of claim 1, wherein said primary optic comprises an overhang portion.

7. The light emitter package of claim 1, wherein said primary optic comprises an asymmetrical shape.

8. The light emitter package of claim 1, wherein said primary optic includes wavelength conversion material.

9. The light emitter package of claim 1, further comprising a wavelength conversion material over said primary optic.

10. The light emitter package of claim 1, wherein said intermediate element includes a wavelength conversion material.

11. The light emitter package of claim 1, wherein said intermediate element is comprised of a material which is sacrificial.

12. The light emitter package of claim 11 wherein said material is selected from the group consisting of thermoplastic polymers, polyvinyl alcohol, wax, and soluble plastics.

13. The light emitter package of claim 1, wherein said intermediate element is permanent.

14. The light emitter package of claim 1, further comprising a secondary optic over said primary optic.

15. The light emitter package of claim 1, wherein said intermediate element further comprises an air gap within said intermediate element.

16. The light emitter package of claim 1, wherein at least a portion of said intermediate element is reflective.

17. An array of light emitter packages, comprising:

a plurality of light emitters disposed on a surface;

at least one intermediate element on said surface at least partially surrounding said light emitters, each of said intermediate elements configured such that at least a portion of said intermediate element can be removed; and

an encapsulant over each of said light emitters forming primary optics, said at least one intermediate element at least partially defining the shape of said primary optics.

18. The array of light emitter packages of claim 17, wherein at least some of said plurality of light emitters comprise LEDs.

19. The array of light emitter packages of claim 17, wherein said intermediate element includes a plurality of meniscus forming features.

20. The array of light emitter packages of claim 17, wherein said primary optics have an exit face and have a tapered shape such that at least a portion closer to the base of said primary optics is narrower than at least a portion closer to the exit face.

21. The array of light emitter packages of claim 17 wherein said primary optics comprise an overhang portion.

22. The array of light emitter packages of claim 17, wherein said primary optics comprise an asymmetrical shape.

23. The array of light emitter packages of claim 17, further comprising a wavelength conversion material.

24. The array of light emitter packages of claim 17, wherein said intermediate element is comprised of a material which is sacrificial.

25. The array of light emitter packages of claim 17, wherein said intermediate element is permanent.

26. The array of light emitter packages of claim 17, wherein said intermediate element further comprises an air gap within said intermediate element.

27. The array of light emitter packages of claim 17, wherein at least a portion of said intermediate element is reflective.