Ceramic-based light emitting diode (LED) devices, components, and methods
First Claim
Patent Images
1. A light emitter device component comprising:
- a non-metallic body having a top surface and a bottom surface opposing the top surface;
at least one or more base layer coupled to the bottom surface and extending beyond at least a portion of a footprint of the non-metallic body, the one or more base layer comprising a substrate bonded to one of a reflective film or a reflective foil positioned against the bottom surface of the non-metallic body, the substrate comprising aluminum;
one or more light emitter devices mounted on the top surface, the non-metallic body having a width that is greater than a width of the one or more light emitter devices; and
one or more electrical components mounted on the top surface separate from the one or more light emitter devices but electrically coupled to the one or more light emitter devices;
wherein the non-metallic body has a porosity such that the non-metallic body is configured to reflect a portion of light emitted by the one or more light emitter devices but allow some of the light emitted to be transmitted to the bottom surface; and
wherein the reflective film or reflective foil is positioned to reflect the light transmitted to the bottom surface.
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Abstract
Devices, components and methods containing one or more light emitter devices, such as light emitting diodes (LEDs) or LED chips, are disclosed. In one aspect, a light emitter device component can include a ceramic body having a top surface, one or more light emitter devices mounted directly or indirectly on the top surface, and one or more electrical components mounted on the top surface and electrically coupled to the one or more light emitter devices, wherein the one or more electrical components can be spaced from the ceramic body by one or more non-metallic layers. Components disclosed herein can result in improved light extraction and thermal management.
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Citations
39 Claims
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1. A light emitter device component comprising:
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a non-metallic body having a top surface and a bottom surface opposing the top surface; at least one or more base layer coupled to the bottom surface and extending beyond at least a portion of a footprint of the non-metallic body, the one or more base layer comprising a substrate bonded to one of a reflective film or a reflective foil positioned against the bottom surface of the non-metallic body, the substrate comprising aluminum; one or more light emitter devices mounted on the top surface, the non-metallic body having a width that is greater than a width of the one or more light emitter devices; and one or more electrical components mounted on the top surface separate from the one or more light emitter devices but electrically coupled to the one or more light emitter devices; wherein the non-metallic body has a porosity such that the non-metallic body is configured to reflect a portion of light emitted by the one or more light emitter devices but allow some of the light emitted to be transmitted to the bottom surface; and wherein the reflective film or reflective foil is positioned to reflect the light transmitted to the bottom surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 37)
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13. A method of forming a light emitter device component, the method comprising:
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coupling a bottom surface of a non-metallic body to one or more base layer comprising a substrate bonded to one of a reflective film or a reflective foil positioned against the bottom surface of the non-metallic body, the substrate comprising aluminum, and the one or more base layer extending beyond at least a portion of a footprint of the non-metallic body; mounting one or more light emitter devices on a top surface of the non-metallic body opposing the bottom surface without metal layers at a die attach interface, the non-metallic body having a width that is greater than a width of the one or more light emitter devices; providing one or more non-metallic layer on the top surface of the non-metallic body; and mounting one or more electrical components to the one or more non-metallic layer and electrically coupling the one or more electrical components to the one or more light emitter devices; wherein the non-metallic body has a porosity such that the non-metallic body is configured to reflect a portion of light emitted by the one or more light emitter devices but allow some of the light emitted to be transmitted to the bottom surface; and wherein the reflective film or reflective foil is positioned to reflect the light transmitted to the bottom surface. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A light emitter device component comprising:
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a non-metallic body having a top surface and a bottom surface opposing the top surface; at least one base layer coupled against the bottom surface of the body, the base layer comprising a substrate bonded to one of a reflective film or a reflective foil, the substrate comprising aluminum; the base layer being adapted for attachment to another structure; one or more light emitter devices mounted over the top surface of the body, the non-metallic body having a width that is greater than a width of the one or more light emitter devices; and one or more electrical components mounted on the top surface separate from the one or more light emitter devices but electrically coupled to the one or more light emitter devices; wherein the non-metallic body has a porosity such that the non-metallic body is configured to reflect a portion of light emitted by the one or more light emitter devices but allow some of the light emitted to be transmitted to the bottom surface; and wherein the at least one base layer is positioned to reflect the light transmitted to the bottom surface. - View Dependent Claims (26, 27, 28, 29, 30, 38)
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31. A method of forming a light emitter device component, the method comprising:
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coupling a bottom surface of a non-metallic body against at least one base layer, the base layer comprising a substrate bonded to one of a reflective film or a reflective foil and being adapted for attachment to another structure, the substrate comprising aluminum; mounting one or more light emitter devices on a top surface of the non-metallic body, the non-metallic body having a width that is greater than a width of the one or more light emitter devices; and mounting one or more electrical components to the top surface of the non-metallic body separate from the one or more light emitter devices and electrically coupling the one or more electrical components to the one or more light emitter devices; wherein the non-metallic body has a porosity such that the non-metallic body is configured to reflect a portion of light emitted by the one or more light emitter devices but allow some of the light emitted to be transmitted to the bottom surface; and wherein the at least one base layer is positioned to reflect the light transmitted to the bottom surface. - View Dependent Claims (32, 33, 34, 35, 39)
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36. A light emitter device component comprising:
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a non-metallic body having a top surface and a bottom surface opposing the top surface; at least one or more base layer coupled to the bottom surface and extending beyond a footprint of the non-metallic body, the one or more base layer comprising at least one reflective material layer positioned against the bottom surface of the non-metallic body; an array of light emitter devices mounted on the top surface, the non-metallic body having a width that is greater than a width of each light emitter device of the array of light emitter devices; and one or more electrical components mounted on the top surface and electrically coupled to the array of light emitter devices; wherein the non-metallic body has a porosity configured to provide between about 50 percent and about 90 percent total reflection such that the non-metallic body is configured to reflect a portion of light emitted by the array of light emitter devices but allow some of the light emitted to be transmitted to the bottom surface; and wherein the at least one reflective material layer is positioned to reflect the light transmitted to the bottom surface.
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Specification