Packaging designs for LEDs

• US 7,170,100 B2
• Filed: 08/23/2005
• Issued: 01/30/2007
• Est. Priority Date: 01/21/2005
• Status: Active Grant

• Current Assignee: Formosa Epitaxy Incorporated (Epistar Corporation)
• Original Assignee: Luminus Devices Incorporated (Sanan Optoelectronics Company Limited)
• Inventors: Panaccione, Paul, Karlicek, Robert F. Jr., Lim, Michael, Erchak, Alexei A., Lidorikis, Elefterios, Venezia, Jo A., Hoepfner, Christian
• Primary Examiner(s): Prenty; Mark V.
• Application Number:
  US11/209,957
• Publication Number:
  US 20060163587A1
• Time in Patent Office: 525 Days
• Field of Search: 257/79, 257/88, 257/89, 257/95, 257/98, 257/99, 257/712
• US Class Current: 257/88
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/73265 Layer and wire connectors
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• 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 2924/01012 Magnesium [Mg]
• CPC Class Codes: H01L 2924/01046 Palladium [Pd]
• CPC Class Codes: H01L 2924/01078 Platinum [Pt]
• CPC Class Codes: H01L 2924/01079 Gold [Au]
• CPC Class Codes: H01L 2924/12041 LED
• CPC Class Codes: H01L 2924/12044 OLED
• CPC Class Codes: H01L 33/56 Materials, e.g. epoxy or silicone resin
• CPC Class Codes: H01L 33/62 Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls

Abstract

Light-emitting devices, and related components, processes, systems and methods are disclosed.

Claims

1. A system comprising:

a substrate;

an array of light emitting devices supported by the substrate, the array having an outer perimeter that defines an area, the array of light emitting devices being positioned such that a ratio of a sum of a total area of all of the light emitting devices in the array of light emitting devices to the area defined by the outer perimeter is at least about 0.75; and

a package containing the substrate and the array of light emitting devices, the package having a layer configured so that at least about 75% of the light that emerges from the light emitting devices and impinges on the layer passes through the layer,

wherein the layer is disposed such that a distance between a surface of the array of light emitting devices and a surface of the layer nearest to the surface of the array of light emitting devices is from about five microns to about 400 microns.

2. The system of claim 1, wherein the array of light emitting devices comprises four light emitting devices.

3. The system of claim 1, wherein the array of light emitting devices consists of four light emitting devices.

4. The system of claim 3, wherein the four light emitting devices are disposed in a rectangular matrix having two rows and two columns.

5. The system of claim 3, wherein the four light emitting devices are disposed in a rectangular matrix having one row and four columns.

6. The system of claim 1, wherein the array of light emitting devices comprises six light emitting devices.

7. The system of claim 1, wherein the array of light emitting devices consists of six light emitting devices.

8. The system of claim 7, wherein the six light emitting devices are disposed in a rectangular matrix having two rows and three columns.

9. The system of claim 7, wherein the six light emitting devices are disposed in a rectangular matrix having one row and six columns.

10. The system of claim 1, wherein the array of light emitting devices consists of 2*N light emitting devices where N is a positive integer and the 2*N light-emitting devices are disposed in a rectangular matrix having N rows and two columns.

11. The system of claim 1, wherein the array of light emitting devices comprises two light emitting devices.

12. The system of claim 1, wherein the array of light emitting devices consists of two light emitting devices.

13. The system of claim 1, wherein the array of light emitting devices comprises a red light emitting device, a green light emitting device, and a blue light emitting device.

14. The system of claim 1, wherein an aspect ratio of the array of light emitting devices is about 16:

9.

15. The system of claim 1, wherein an aspect ratio of the array of light emitting devices is about 4×

3.

16. The system of claim 1, wherein an aspect ratio of each of the light emitting devices in the array of light emitting devices is about 4×

3.

17. The system of claim 1, wherein an aspect ratio of each of the light emitting devices in the array of light emitting devices is about 16×

9.

21. The system of claim 1, wherein the package further includes a heat sink layer.

22. The system of claim 1, wherein the package is mounted on a heat sink device.

23. The system of claim 1, wherein the package includes a package substrate.

24. The system of claim 23, wherein the package substrate contains of Al, N, Cu, C, Au or combinations thereof.

25. The system of claim 1, wherein the package is mounted on a thermoelectric cooler.

26. The system of claim 1, wherein at least one of the light emitting devices in the array of light emitting devices comprises a light emitting diode.

27. The system of claim 26, wherein the light emitting diode is a photonic lattice light emitting diode.

28. The system of claim 1, wherein the light emitting device is a surface emitting laser.

29. The system of claim 1, further comprising a cooling system configured so that, during use, the cooling system regulates a temperature of the light emitting diode.

30. The system of claim 1, wherein at least one of the light emitting devices in the array of light emitting devices comprises a first layer supported by a light generating region, a surface of the first layer being configured so that light generated by the light generating region can emerge from the light emitting device via a surface of the first layer, the surface of the first layer having a dielectric function that varies spatially according to a pattern.

31. The system of claim 30, wherein the pattern has an ideal lattice constant and a detuning parameter with a value greater than zero.

32. The system of claim 30, wherein the pattern comprises a nonperiodic pattern.

33. The system of claim 30, wherein the pattern comprises a quasiperiodic pattern.

34. The system of claim 30, wherein the pattern comprises a complex periodic pattern.

35. The system of claim 30, wherein the pattern comprises a periodic pattern.

36. The system of claim 1, wherein the array of light emitting devices comprises a plurality of light emitting devices connected electrically in series.

37. The system of claim 1, wherein the array of light emitting devices comprises a plurality of light emitting devices connected electrically in parallel.

38. The system of claim 1, wherein the ratio of the sum of the total area of all of the light emitting devices in the array of light emitting devices to the area defined by the outer perimeter is at least about 0.8.

39. The system of claim 1, wherein the ratio of the sum of the total area of all of the light emitting devices in the array of light emitting devices to the area defined by the outer perimeter is at least about 0.85.

40. The system of claim 1, wherein the ratio of the sum of the total area of all of the light emitting devices in the array of light emitting devices to the area defined by the outer perimeter is at least about 0.9.

55. The system of claim 1, wherein the layer is disposed such that a ratio of a length of an edge of at least one of the light emitting devices to a distance between a surface of the at least one light emitting device and a surface of the layer is at least about 10.

90. The system of claim 1, further comprising at least one optical component.

91. The system of claim 1, wherein the layer is disposed such that a distance between a surface of the array of light emitting devices and a surface of the layer nearest to the surface of the array of light emitting devices is from about five microns to about 200 microns.

92. The system of claim 1, wherein at least one of the light-emitting devices has an edge that is at least about one millimeter long.

18. A system comprising:

a substrate;

an array of light emitting devices supported by the substrate, the array having an outer perimeter that defines an area, the array of light emitting devices being positioned such that a ratio of a sum of a total area of all of the light emitting devices in the array of light emitting devices to the area defined by the outer perimeter is at least about 0.75; and

a package containing the substrate and the array of light emitting devices, the package having a layer configured so that at least about 75% of the light that emerges from the light emitting devices and impinges on the layer passes through the layer,

wherein the layer is disposed such that a ratio of a length of an edge of at least one of the light emitting devices to a distance between a surface of the at least one light emitting device and a surface of the layer is at least about 10.

41. The system of claim 18, wherein the array of light emitting devices comprises four light emitting devices.

42. The system of claim 41, wherein the four light emitting devices are disposed in a rectangular matrix having two rows and two columns.

43. The system of claim 41, wherein the four light emitting devices are disposed in a rectangular matrix having one row and four columns.

44. The system of claim 18, wherein the array of light emitting devices comprises six light emitting devices.

45. The system of claim 44, wherein the six light emitting devices are disposed in a rectangular matrix having two rows and three columns.

46. The system of claim 44, wherein the six light emitting devices are disposed in a rectangular matrix having one row and six columns.

47. The system of claim 18, wherein the array of light emitting devices consists of 2*N light emitting devices where N is a positive integer and the 2*N light-emitting devices are disposed in a rectangular matrix having N rows and two columns.

48. The system of claim 18, wherein the array of light emitting devices comprises two light emitting devices.

49. The system of claim 18, wherein the array of light emitting devices consists of two light emitting devices.

50. The system of claim 18, wherein the array of light emitting devices comprises a red light emitting device, a green light emitting device, and a blue light emitting device.

51. The system of claim 18, wherein an aspect ratio of the array of light emitting devices is about 16:

9.

52. The system of claim 18, wherein an aspect ratio of the array of light emitting devices is about 4×

3.

53. The system of claim 18, wherein an aspect ratio of each of the light emitting devices in the array of light emitting devices is about 4×

3.

54. The system of claim 18, wherein an aspect ratio of each of the light emitting devices in the array of light emitting devices is about 16×

9.

56. The system of claim 18, wherein the layer being is such that a distance between the surface of the array of light emitting devices and a surface of the layer nearest to the surface of the array of light emitting devices is from about five microns to about 400 microns.

57. The system of claim 18, wherein the layer further comprises at least one optical component.

58. The system of claim 57, wherein the optical component is an optical component selected from the group consisting of a photonic lattice, a color filter, a polarization selective layer, a phosphor layer, an anti-reflective coating.

59. The system of claim 18, wherein the package further includes a heat sink layer.

60. The system of claim 18, wherein the package is mounted on a heat sink device.

61. The system of claim 18, wherein the package includes a package substrate.

62. The system of claim 61, wherein the package substrate contains of Al, N, Cu, C, Au or combinations thereof.

63. The system of claim 18, wherein the package is mounted on a thermoelectric cooler.

64. The system of claim 18, wherein at least one of the light emitting devices in the array of light emitting devices comprises a light emitting diode.

65. The system of claim 64, wherein the light emitting diode is a photonic lattice light emitting diode.

66. The system of claim 18, wherein the light emitting device is a surface emitting laser.

67. The system of claim 18, further comprising a cooling system configured so that, during use, the cooling system regulates a temperature of the light emitting diode.

68. The system of claim 18, wherein at least one of the light emitting devices in the array of light emitting devices comprises a first layer supported by a light generating region, a surface of the first layer being configured so that light generated by the light generating region can emerge from the light emitting device via a surface of the first layer, the surface of the first layer having a dielectric function that varies spatially according to a pattern.

69. The system of claim 68, wherein the pattern has an ideal lattice constant and a detuning parameter with a value greater than zero.

70. The system of claim 68, wherein the pattern comprises a nonperiodic pattern.

71. The system of claim 68, wherein the pattern comprises a quasicrystalline pattern.

72. The system of claim 68, wherein the pattern comprises a complex periodic pattern.

73. The system of claim 68, wherein the pattern comprises a periodic pattern.

74. The system of claim 18, wherein the array of light emitting devices comprises a plurality of light emitting devices connected electrically in series.

75. The system of claim 18, wherein the array of light emitting devices comprises a plurality of light emitting devices connected electrically in parallel.

93. The system of claim 18, wherein the ratio of the sum of the total area of all of the light emitting devices in the array of light emitting devices to the area defined by the outer perimeter is at least about 0.85.

94. The system of claim 18, wherein the layer is disposed such that a distance between a surface of the array of light emitting devices and a surface of the layer nearest to the surface of the array of light emitting devices is from about five microns to about 200 microns.

95. The system of claim 18, wherein at least one of the light-emitting devices has an edge that is at least about one millimeter long.

96. The system of claim 18, wherein the layer is disposed such that a ratio of a length of an edge of at least one of the light emitting devices to a distance between a surface of the at least one light emitting device and a surface of the layer is at least about 20.

19. A system comprising:

a substrate

an array of light emitting devices supported by the substrate, the array having an outer perimeter that defines an area, the array of light emitting devices being positioned such that a ratio of a sum of a total area of all of the light emitting devices in the array of light emitting devices to the area defined by the outer perimeter is at least about 0.75; and

a package containing the substrate and the array of light emitting devices, the package having a layer configured so that at least about 75% of the light that emerges from the light emitting devices and impinges on the layer passes through the layer,

wherein the layer further comprises at least one optical component.

20. The system of claim 19, wherein the optical component is an optical component selected from the group consisting of a photonic lattice, a color filter, a polarization selective layer, a wavelength conversion layer, and an anti-reflective coating.

97. The system of claim 19, wherein an aspect ratio of the array of light emitting devices is about 16:

9.

98. The system of claim 19, wherein an aspect ratio of the array of light emitting devices is about 4×

3.

99. The system of claim 19, wherein an aspect ratio of each of the light emitting devices in the array of light emitting devices is about 4×

3.

100. The system of claim 19, wherein an aspect ratio of each of the light emitting devices in the array of light emitting devices is about 16×

9.

101. The system of claim 19, wherein at least one of the light emitting devices in the array of light emitting devices comprises a light emitting diode.

102. The system of claim 100, wherein the light emitting diode is a photonic lattice light emitting diode.

103. The system of claim 19, wherein at least one of the light emitting devices in the array of light emitting devices comprises a first layer supported by a light generating region, a surface of the first layer being configured so that light generated by the light generating region can emerge from the light emitting device via a surface of the first layer, the surface of the first layer having a dielectric function that varies spatially according to a pattern.

104. The system of claim 19, wherein the layer is disposed such that a distance between a surface of the array of light emitting devices and a surface of the layer nearest to the surface of the array of light emitting devices is from about five microns to about 400 microns.

105. The system of claim 19, wherein the layer is disposed such that a ratio of a length of an edge of at least one of the light emitting devices to a distance between a surface of the at least one light emitting device and a surface of the layer is at least about 10.

76. A system comprising:

an array of light emitting devices comprising;

a first rectangular light emitting device having a first edge and a second edge, the first edge of the first light emitting device being approximately perpendicular to the second edge of the first light emitting device;

a second rectangular light emitting device having a first edge and a second edge, the first edge of the second light emitting device being approximately perpendicular to the second edge of the second light emitting device, the second light emitting device being disposed such that the second edge of the second light emitting device is approximately parallel to the second edge of the first light emitting device and a distance between the second edge of the second light emitting and the second edge of the first light emitting device is at most about 200 microns;

a third rectangular light emitting device having a first edge and a second edge, the first edge of the third light emitting device being approximately perpendicular to the second edge of the third light emitting device, the third light emitting device being disposed such that the first edge of the third light emitting device is approximately parallel to the first edge of the first light emitting device and a distance between the first edge of the third light emitting and the first edge of the first light emitting device is at most about 200 microns;

a fourth rectangular light emitting device having a first edge and a second edge, the first edge of the fourth light emitting device being approximately perpendicular to the second edge of the fourth light emitting device, the fourth light emitting device being disposed such that;

the first edge of the fourth light emitting device is approximately parallel to the first edge of the second light emitting device and a distance between the first edge of the fourth light emitting device and the first edge of the second light emitting device is at most about 200 microns, and

the second edge of the fourth light emitting device is approximately parallel to the second edge of the third light emitting device and a distance between the second edge of the fourth light emitting device and the second edge of the third light emitting device is at most about 200 microns; and

a package containing the array of light emitting devices, the package having a layer configured so that at least about 75% of the light that that emerges from the light emitting device and impinges on the layer passes through the layer.

77. The system of claim 76, wherein an aspect ratio of the array of light emitting devices is about 16:

9.

78. The system of claim 76, wherein an aspect ratio of the array of light emitting devices is about 4×

3.

79. The system of claim 76, wherein an aspect ratio of each light emitting device of the array of light emitting devices is about 16:

9.

80. The system of claim 76, wherein an aspect ratio each light emitting device of the array of light emitting devices is about 4×

3.

81. The system of claim 76, wherein at least one of the first, second, third and forth light emitting devices in the array of light emitting devices comprises a first layer supported by a light generating region, a surface of the first layer being configured so that light generated by the light generating region can emerge from the light emitting device via a surface of the first layer, the surface of the first layer having a dielectric function that varies spatially according to a pattern.

82. The system of claim 81, wherein the pattern has an ideal lattice constant and a detuning parameter with a value greater than zero.

83. The system of claim 81, wherein the pattern comprises a nonperiodic pattern.

84. The system of claim 81, wherein the pattern comprises a quasicrystalline pattern.

85. The system of claim 81, wherein the pattern comprises a complex periodic pattern.

86. The system of claim 81, wherein the pattern comprises a periodic pattern.

87. The system of claim 76, wherein the array of light emitting devices further compries:

a fifth rectangular light emitting device having a first edge and a second edge, the first edge of the fifth light emitting device being approximately perpendicular to a second edge of the fifth light emitting device, the fifth light emitting device being disposed such that the first edge of the fifth light emitting device is approximately parallel to a third edge of the second light emitting device and a distance between the first edge of the fifth light emitting and the third edge of the second light emitting device is at most about 200 microns;

a sixth rectangular light emitting device having a first edge and a second edge, the first edge of the sixth light emitting device being approximately perpendicular to the second edge of the sixth light emitting device, the fourth light emitting device being disposed such that;

the first edge of the sixth light emitting device is approximately parallel to the second edge of the fifth light emitting device and a distance between the first edge of the sixth light emitting device and the second edge of the fifth light emitting device is at most about 200 microns, and

the second edge of the sixth light emitting device is approximately parallel to a third edge of the fourth light emitting device and a distance between the second edge of the sixth light emitting device and the third edge of the fourth light emitting device is at most about 200 microns.

88. The system of claim 76, wherein the array of light emitting devices comprises a plurality of light emitting devices connected electrically in series.

89. The system of claim 76, wherein the array of light emitting devices comprises a plurality of light emitting devices connected electrically in parallel.