LED package and method for manufacturing the LED package

• US 9,593,810 B2
• Filed: 09/16/2008
• Issued: 03/14/2017
• Est. Priority Date: 09/20/2007
• Status: Active Grant

• Current Assignee: Lumileds LLC (Apollo Global Management, Inc.)
• Original Assignee: Koninklijke Philips N.V.
• Inventors: Kloosterman, Jan, Willwohl, Harald, Sweegers, Norbertus Antonius Maria
• Primary Examiner(s): Gramling, Sean
• Assistant Examiner(s): Sufleta, II, Gerald J
• Application Number:
  US12/678,321
• Publication Number:
  US 20100284198A1
• Time in Patent Office: 3,101 Days
• Field of Search: 362/294, 362/311.02, 362/249.02, 257/797
• US Class Current: 1/1
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21K 9/66 Details of globes or covers forming part of the light source
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21S 41/143 the main emission direction of the LED being parallel to the optical axis of the illuminating device
• CPC Class Codes: F21S 41/151 arranged in one or more lines
• CPC Class Codes: F21S 41/192 Details of lamp holders, terminals or connectors
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/195 Details of lamp holders, terminals or connectors
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G03B 21/20 Lamp housings
• CPC Class Codes: G03B 21/2033 LED or laser light sources
• CPC Class Codes: H01L 2223/54426 for alignment
• CPC Class Codes: H01L 23/544 Marks applied to semiconductor devices or parts, e.g. registration marks, alignment structures, wafer maps test patterns for characterising or monitoring manufacturing processes H01L22/00
• CPC Class Codes: H05K 1/0269 for visual or optical inspection
• CPC Class Codes: H05K 3/303 Surface mounted components, e.g. affixing before soldering, aligning means, spacing means H05K3/32 takes precedence

Abstract

A LED package (10) for use in a lamp as well as a method for manufacturing such kind of a LED package (10) are provided, wherein the LED package (10) comprises at least one LED (16), an optical element (18) for guiding light emitted by the LED (16), a cover (26) for covering at least partially electrical components (20, 22, 24) connectable to the LED (16) and at least one optical detectable reference mark (32; 36), wherein the optical element (18) comprises at least one first optical detectable mark (30) and the cover (26) comprises at least one second optical detectable mark (34), whereby the optical element (18) and the cover (26) are arranged and aligned both with respect to the same reference mark (32; 36) by means of the first mark (30) and the second mark (34). Due to the same reference (32; 36) for both the optical element (18) and the cover (26) manufacturing tolerances are not added to each other so that the accuracy of a correct arrangement is increased. Thus, the LED package (10) provides an improved optical performance, particularly an improved brightness and an improved luminous flux.

Claims

1. A device comprising an LED package, the LED package comprising:

at least one LED mounted over a base;

an optical element mounted over the LED and over the base, the optical element configured to guide light emitted by the LED;

a cover mounted over the base and at least partially covering electrical components connected to the LED, wherein the cover is laterally spaced from the optical element to create a gap between the cover and the optical element; and

a plurality of optically detectable reference marks on the base that remain optically detectable within the gap after the optical element and the cover are positioned,

wherein the optical element includes a plurality of first optically detectable marks that are optically detectable along with the reference marks on the base within the gap, and the cover includes a plurality of second optically detectable marks that are optically detectable along with the reference marks on the base within the gap, wherein both the optical element and the cover are arranged and aligned with respect to the same optically detectable reference marks on the base via the first optically detectable marks and the second optically detectable marks, respectively,

wherein the cover further comprises at least three alignment protrusions on its top surface, forming the highest points of the LED package, for concurrently contacting a reference surface during positioning of the package in a housing for positioning the package at a correct height in the housing.

2. The device of claim 1, wherein the base comprises a substrate onto which the LED is mounted.

3. The device of claim 1, wherein the base comprises a heat sink configured to lead heat away from the LED.

4. The device of claim 1, wherein the LED or a lighting field element comprising the LED includes at least one additional optically detectable mark for arranging and aligning the LED or the lighting field element with respect to the same optically detectable reference marks.

5. The device of claim 1, wherein a thermal barrier is provided between the cover and at least one of the LED and the optical element.

6. The device of claim 1, wherein the cover has a heat resistance which is less than a heat resistance of the optical element.

7. The device of claim 1, wherein the cover comprises at least one tapered, connection opening for connecting the cover via the connection opening.

8. The device of claim 1, comprising a housing to which the LED package is connected via the cover, wherein the housing comprises at least one lens arranged adjacent to the optical element.

9. The device of claim 1, wherein at least one of the optically detectable reference marks, the first optically detectable marks, and the second optically detectable marks have a shape of a cross.

10. The device of claim 1, wherein the optically detectable reference marks have a shape of a cross.

11. A method of manufacturing and positioning a LED package, comprising:

providing at least one LED mounted over a base;

mounting an optical element over the LED and over the base, the optical element configured to guide light emitted by the LED, the optical element including a plurality of first optically detectable marks;

mounting a cover over the base, the cover at least partially covering electrical components connected to the LED, the cover including a plurality of second optically detectable marks, wherein the cover is laterally spaced from the optical element to create a gap between the cover and the optical element;

providing a plurality of optically detectable reference marks on the base that remain optically detectable within the gap after the optical element and the cover are positioned;

wherein mounting the optical element comprises arranging and aligning the optical element with respect to the optically detectable reference marks within the gap via the first optically detectable marks by means of an optical system;

wherein mounting the cover comprises arranging and aligning the cover with respect to the same optically detectable reference marks via the second optically detectable marks by means of the optical system, such that the optically detectable reference marks remain optically detectable after the optical element and the cover are mounted over the base; and

wherein the cover further comprises at least three alignment protrusions on its top surface, forming the highest points of the LED package, the method further comprising positioning the package in a housing such that the three alignment protrusions concurrently contact a reference surface in the housing for positioning the package at a correct height in the housing.

12. The method of claim 11, wherein at least one of the optically detectable reference marks, the first optically detectable marks, and the second optically detectable marks have a shape of a cross.

13. The method of claim 11, wherein the optically detectable reference marks have a shape of a cross.

14. An LED package, comprising:

a substrate;

at least one LED arranged on the substrate;

a heat sink configured to lead heat away from the LED, the heat sink being thermally connected to the LED;

an optical element mounted over the LED and configured to guide light emitted by the LED, the optical element having a plurality of first optically detectable marks provided thereon; and

a cover at least partially covering electrical components connected to the LED, the cover having a plurality of second optically detectable marks provided thereon, wherein the cover is laterally spaced from the optical element to create a gap between the cover and the optical element;

wherein one of the substrate and the heat sink has a plurality of optically detectable reference marks provided thereon,

wherein both the optical element and the cover are arranged and aligned with respect to the same optically detectable reference marks within the gap via the first optically detectable marks and the second optically detectable marks, respectively, such that the optically detectable reference marks remain optically detectable after the optical element and the cover have been arranged and aligned with respect to the same optically detectable reference marks, and

wherein the cover further comprises at least three alignment protrusions on its top surface, forming the highest points of the LED package, for concurrently contacting a reference surface during positioning of the package in a housing for positioning the package at a correct height in the housing.

15. The LED package of claim 14, wherein the substrate has the optically detectable reference marks provided thereon.

16. The LED package of claim 14, wherein the heat sink has the optically detectable reference marks provided thereon.

17. The LED package of claim 14, wherein at least one of the optically detectable reference marks, the first optically detectable marks, and the second optically detectable marks have a shape of a cross.

18. The LED package of claim 14, wherein the optically detectable reference marks have a shape of a cross.