Light emitter devices having improved light output and related methods

• US 9,343,441 B2
• Filed: 04/11/2012
• Issued: 05/17/2016
• Est. Priority Date: 02/13/2012
• Status: Active Grant

• Current Assignee: Creeled Incorporated
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Reiherzer, Jesse Colin
• Primary Examiner(s): Patel, Nimeshkumar
• Assistant Examiner(s): QUARTERMAN, KEVIN J
• Application Number:
  US13/444,399
• Publication Number:
  US 20130207130A1
• Time in Patent Office: 1,497 Days
• Field of Search: 313498-512, 313/112
• US Class Current: 1/1
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2224/49113 the connectors connecting different bonding areas on the semiconductor or solid-state body to a common bonding area outside the body, e.g. converging wires
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• 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 33/486 adapted for surface mounting
• CPC Class Codes: H01L 33/54 having a particular shape
• CPC Class Codes: H01L 33/56 Materials, e.g. epoxy or silicone resin

Abstract

Light emitter devices having improved light output and related methods are disclosed. In one embodiment, light emitter devices can include a light emission area including one or more light emitting chips. The emitter device can further include a filling material at least partially disposed over the one or more light emitting chips. The filling material can include a first discrete layer of phosphor containing material and a second discrete layer of optically clear material. The device can optionally include more than one discrete layer of optically clear material. Each of the discrete layers of material can be separately dispensed within the light emission area such that the filling material is dispensed to a level that is substantially flush with an upper surface of the emitter device.

Claims

1. A light emitter device comprising:

a light emission area comprising one or more light emitting chips; and

a filling material at least partially disposed over the one or more light emitting chips, wherein the filling material comprises;

a first discrete layer of phosphor containing material; and

second and third discrete layers of optically clear material; and

wherein the first discrete layer of phosphor containing material is disposed between and contacts each of the second and third discrete layers of optically clear material, wherein the second discrete layer of optically clear material contacts the one or more light emitter chips, and wherein each of the first, second, and third discrete layers of material are approximately a same thickness.

2. The device of claim 1, wherein the first discrete layer of phosphor containing material comprises one or more phosphors disposed in a low refractive index (RI) silicone encapsulant having a RI of approximately 1.4 or less.

3. The device of claim 1, wherein the first discrete layer of phosphor containing material comprises one or more phosphors disposed in a high refractive index (RI) silicone encapsulant having a RI of approximately 1.5 or more.

4. The device of claim 1, wherein the first discrete layer of phosphor containing material comprises one or more phosphors disposed in a medium refractive index (RI) silicone encapsulant having a RI of approximately 1.4 to 1.5.

5. The device of claim 1, wherein the second and third discrete layers of optically clear material comprise a silicone, epoxy, or glass material.

6. The device of claim 5, wherein the silicone material comprises a low refractive index (RI) silicone encapsulant having a RI of approximately 1.4 or less.

7. The device of claim 5, wherein the silicone material comprises a high refractive index (RI) silicone encapsulant having a RI of approximately 1.5 or more.

8. The device of claim 5, wherein the silicone material comprises a medium refractive index (RI) silicone encapsulant having a RI of approximately 1.4 to 1.5.

9. The device of claim 1, wherein each of the second and third discrete layers of optically clear material increases a distance between the one or more light emitting chips and an air interface by approximately 0.2 and 0.5 mm.

10. The device of claim 1, wherein a distance between the one or more light emitting chips and an air interface can be increased to approximately 2 mm by increasing one or more walls of the light emission area by approximately 0.2 mm to 1.5 MM.

11. The device of claim 1, wherein a retention material is disposed about the light emission area.

12. The device of claim 11, wherein a distance between the one or more light emitting chips and an air interface is increased by a secondary dam dispensed about the retention material.

13. The device of claim 12, wherein the secondary dam is taller than the retention material.

14. The device of claim 5, wherein the third discrete layer of optically material comprises glass.

15. The device of claim 1, wherein each of the discrete layers of material is approximately 0.2 millimeters (mm) to 0.4 mm thick.

16. The device of claim 1, further comprising a fourth discrete layer of phosphor containing material.

17. The device of claim 1, wherein the light emission area comprises a cavity with the one or more light emitting chips disposed therein.

18. The device of claim 17, wherein the cavity comprises a cavity volume and approximately 50% of the cavity volume is filled with the first discrete layer of material, approximately 25% of the cavity volume is filled with the second discrete layer of material, and approximately 25% of the cavity volume is filled with the third discrete layer of material.

19. The device of claim 17, wherein the cavity comprises a cavity volume and approximately 40% of the cavity volume is filled with the first discrete layer of material, approximately 30% of the cavity volume is filled with the second discrete layer of material, and approximately 30% of the cavity volume is filled with the third discrete layer of material.

20. The device of claim 1, wherein the device comprises a light output of approximately 1160 to 1190 lumens (lm) at 270 mA.

21. A light emitter device comprising:

a light emission area comprising a cavity with one or more light emitting chips disposed therein; and

a filling material at least partially disposed over the one or more light emitting chips, wherein the filling material comprises;

a first discrete layer of phosphor containing material; and

a plurality of discrete layers of optically clear material, wherein each of the plurality of layers comprises a same refractive index (RI) value of between approximately 1.4 and 2.0;

wherein the cavity comprises a cavity volume and at least approximately 25% of the cavity volume is filled with the first discrete layer of material and at least approximately 25% of the cavity volume is filled with the plurality of discrete layers of optically clear material.

22. The device of claim 21, wherein approximately 50% of the cavity volume is filled with the first discrete layer of material and approximately 50% of the cavity volume is filled with the plurality of discrete layers of optically clear material.

23. The device of claim 21, wherein approximately 25% of the cavity volume is filled with the first discrete layer of material and approximately 75% of the cavity volume is filled with the plurality of discrete layers of optically clear material.

24. The device of claim 21, wherein approximately 75% of the cavity volume is filled with the first discrete layer of material and approximately 25% of the cavity volume is filled with the plurality of discrete layers of optically clear material.

25. The device of claim 21, further comprising a plurality of discrete layers of phosphor containing material.

26. The device of claim 25, wherein the plurality of discrete layers of phosphor containing material alternate with the plurality of discrete layers of optically clear material within the cavity.

27. A light emitter device comprising:

a light emission area comprising one or more light emitting chips; and

a filling material at least partially disposed over the one or more light emitting chips, wherein the filling material comprises;

a first discrete layer of phosphor containing material contacting the one or more light emitter chips; and

a second discrete layer of optically clear material;

wherein the second discrete layer of optically clear material is disposed directly over an upper surface of the first discrete layer of phosphor containing material; and

wherein the first and second discrete layers of material are approximately a same thickness.

28. The device of claim 27, wherein the first discrete layer of phosphor containing material comprises one or more phosphors disposed in a low refractive index (RI) silicone encapsulant having a RI of approximately 1.4 or less.

29. The device of claim 27, wherein the first discrete layer of phosphor containing material comprises one or more phosphors disposed in a high refractive index (RI) silicone encapsulant having a RI of approximately 1.5 or more.

30. The device of claim 27, wherein the first discrete layer of phosphor containing material comprises one or more phosphors disposed in a medium refractive index (RI) silicone encapsulant having a RI of approximately 1.4 to 1.5.

31. The device of claim 27, wherein the second discrete layer of optically clear material comprises a silicone, epoxy, or glass material.

32. The device of claim 31, wherein the silicone material comprises a low refractive index (RI) silicone encapsulant having a RI of approximately 1.4 or less.

33. The device of claim 31, wherein the silicone material comprises a high refractive index (RI) silicone encapsulant having a RI of approximately 1.5 or more.

34. The device of claim 31, wherein the silicone material comprises a medium refractive index (RI) silicone encapsulant having a RI of approximately 1.4 to 1.5.

35. The device of claim 27, wherein a retention material is disposed about the light emission area.

36. The device of claim 35, wherein a distance between the one or more light emitting chips and the air interface is increased by a secondary dam dispensed about the retention material.

37. The device of claim 27, wherein filling material comprises a third discrete layer of optically clear material.

38. The device of claim 37, wherein the third discrete layer of optically clear material comprises glass.

39. The device of claim 27, wherein the light emission area comprises a cavity with the one or more light emitting chips disposed therein.

40. The device of claim 39, wherein the cavity comprises a cavity volume and approximately 25% of a cavity volume is filled with the first discrete layer of phosphor containing material and approximately 75% of the cavity volume is filled with the second discrete layer of phosphor containing material.

41. The device of claim 39, wherein the cavity comprises a cavity volume and approximately 75% of the cavity volume is filled with the first discrete layer of phosphor containing material and approximately 25% of the cavity volume is filled with the second discrete layer of phosphor containing material.

42. The device of claim 27, wherein the device comprises a light output of approximately 1160 to 1190 lumens (lm) at 270 mA.