LED packages with mushroom shaped lenses and methods of manufacturing LED light-emitting devices
First Claim
1. A light-emitting device comprising:
- a package including;
a light-emitting side,a top surface,a socket including a socket sidewall and a bottom surface, the socket sidewall disposed between the top surface and the bottom surface of the package, the socket disposed on the light-emitting side of the package;
a cavity having a floor and configured to transmit light to the light emitting side of the package via the socket;
an LED disposed within the cavity and bonded to the floor of the cavity;
a thermal insulation layer disposed within the cavity between the LED and the top surface of the package; and
a luminescent layer within the cavity between the thermal insulation layer and the top surface of the package;
a class lens including a cap and a plug, the cap including an upper surface and a lower surface, the plug including a lower surface and a plug sidewall between the lower surface of the plug and the lower surface of the cap, the plug disposed within the socket and the lower surface of the cap disposed adjacent the top surface of the package; and
an adhesive layer disposed to attach the lower surface of the cap to the top surface of the package, wherein a portion the adhesive layer is disposed between the luminescent layer and the lower surface of the plug.
2 Assignments
0 Petitions
Accused Products
Abstract
Methods of fabricating a light-emitting device are provided. A light-emitting device can be formed from bonding a lens including a plug and a cap to an LED package including a socket configured to receive the plug. The lens can be fabricated using an injection mold formed from a well secured to the LED package and injecting a material into the injection mold to cure into a shape of the lens. The lens can also be fabricated using a blank about the shape of the lens and machining the blank to produce the plug and the cap of the lens. The lens can be bonded to the LED package using a convex bead of adhesive deposited on the surface of the LED package and spreading the adhesive between the lens and the LED package.
-
Citations
25 Claims
-
1. A light-emitting device comprising:
-
a package including; a light-emitting side, a top surface, a socket including a socket sidewall and a bottom surface, the socket sidewall disposed between the top surface and the bottom surface of the package, the socket disposed on the light-emitting side of the package; a cavity having a floor and configured to transmit light to the light emitting side of the package via the socket; an LED disposed within the cavity and bonded to the floor of the cavity; a thermal insulation layer disposed within the cavity between the LED and the top surface of the package; and a luminescent layer within the cavity between the thermal insulation layer and the top surface of the package; a class lens including a cap and a plug, the cap including an upper surface and a lower surface, the plug including a lower surface and a plug sidewall between the lower surface of the plug and the lower surface of the cap, the plug disposed within the socket and the lower surface of the cap disposed adjacent the top surface of the package; and an adhesive layer disposed to attach the lower surface of the cap to the top surface of the package, wherein a portion the adhesive layer is disposed between the luminescent layer and the lower surface of the plug. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 24, 25)
-
-
18. A light-emitting device comprising:
-
a package including; a light-emitting side, a top surface, a socket including a socket sidewall and a bottom surface, the socket sidewall disposed between the top surface and the bottom surface of the package, the socket disposed on the light-emitting side of the package; a cavity having a floor and configured to transmit light to the light emitting side of the package via the socket; an LED disposed within the cavity and bonded to the floor of the cavity; an encapsulation layer disposed within the cavity between the LED and the top surface of the package; and a glass lens including a cap and a plug, the cap including an upper surface and a lower surface, the plug including a lower surface and a plug sidewall between the lower surface of the plug and the lower surface of the cap, the plug disposed within the socket and the lower surface of the cap disposed adjacent the top surface of the package; and an adhesive layer disposed to attach the lower surface of the cap to the top surface of the package, wherein a portion the adhesive layer is disposed between the encapsulation layer and the lower surface of the plug. - View Dependent Claims (19, 20, 21, 22, 23)
-
Specification