Methods and apparatus for forming uniform layers of phosphor material on an LED encapsulation ...

37 Pages·2013·2.02 MB·English

US008247248B2
(12) United States Patent (10) Patent N0.2 US 8,247,248 B2
Ling (45) Date of Patent: Aug. 21, 2012
(54) METHODS AND APPARATUS FOR FORMING 5,851,255 A 12/ 1998 Ohtsuki et a1.
UNIFORM LAYERS 0F PHOSPHOR 6,114,704 A * 9/2000 Buck ........................... .. 250/372
6 123 890 A * 9/2000 MaZurek et al. ............ .. 264/293
MATERIAL ON AN LED ENCAPSULATION ’ ’
STRUCTURE 6,204,523 B1 3/2001 Carey et a1.
6,472,765 B1 10/2002 Sano et al.
6,812,500 B2 11/2004 Reeh et al.
(75) Inventor? Peichillg Ling, San Jose, CA (Us) 6,833,669 B2 * 12/2004 George et a1, ,,,,,,,,,,,,,,, ,, 313/506
7,479,662 B2 1/2009 Soules et al.
(73) Assignee: AchroluX Inc., Santa Clara, CA (US) 7,923,918 B2 4/2011 Tamaki et a1.
2002/0187571 A1 12/2002 Collins, 111 et a1.
( * ) Notice: Subject to any disclaimer, the term of this (Continued)
patent is extended or adjusted under 35
U30 154(1)) by 258 days- FOREIGN PATENT DOCUMENTS
(21) Appl NO _ 12/587 281 WO 2010/132160 11/2010
’ (Continued)
(22) Filed: Oct. 5, 2009
(65) Prior Publication Data OTHER PUBLICATIONS
Us 201 1/0039358 A1 Feb 17 201 1 International Preliminary Report on Patentability, froma correspond
ing foreign application, mailed Nov. 2011, PCT/US10/33319.
Related US. Application Data
(60) Provisional application No. 61/216,374, ?led on May Primary Examiner i Michael Lebentritt
15, 2009, provisional application No. 61/273,129,
?led on Jul‘ 30’ 2009' ASSlSZLlI’lZ Exammer * Karen Kusumakar
(74) Attorney, Agent, or Firm * Fountainhead LaW Group
(51) Int.Cl. P.C.
H01L 21/00 (2006.01)
H01L 33/00 (2010.01)
(52) U.S.Cl. .............. .. 438/27;438/29;438/31;438/69; (57) ABSTRACT
438/72; 438/98; 257/98; 257/99; 257/E33.001;
A method for forming a layer of phosphor material on an LED
257/E33.061; 257/E33.067
encapsulant structure includes forming a layer of a phosphor
(58) Field of Classi?cation Search .................. .. 438/24,
material on a ?rst surface, disposing the ?rst surface to cause
438/26, 27, 29, 31; 257/98il00
the phosphor material to be in contact With a surface of the
See application ?le for complete search history.
LED encapsulant structure, applying a pressure between the
(56) References Cited ?rst surface and the surface of the LED encapsulant structure,
and causing the layer of the phosphor material to be attached
U.S. PATENT DOCUMENTS to the LED encapsulant structure.
3,672,927 A 6/1972 Spiller et al.
5,019,748 A * 5/1991 Appelberg ............... .. 315/169.3
5,068,708 A 11/1991 Newman 23 Claims, 21 Drawing Sheets
US 8,247,248 B2
Page 2
US. PATENT DOCUMENTS 2009/0085049 Al* 4/2009 Kolodin et a1. ............... .. 257/98
2003/0203104 A1 10/2003 Crommentuyn et a1. 5883813353); 21* Z5883 ghlmlsettall' 257/98
2004/0145913 Al* 7/2004 Ouderkirk et a1. .......... .. 362/555 * “none 3' """""""" "
Zoos/0106329 A1 500% Lewisetal‘ 2009/0189179 A1 7/2009 Wen et a1. ................... .. 257/100
2006/0102914 A1* 5/2006 BSlmiotnsd eert ea1t‘ a1‘' 257/98 2010/0065864 A1 3/2010 KSeOhsIsle lest ea1t.a l.. . . . . . . . . . . . . ..
2006/0171152 Al* 8/2006 Suehiro et a1. .............. .. 362/363 2010/0119839 A1 5/2010 Chen
2006/0260943 A1 11/2006 Khaselev etal. 2010/0189429 Al* 7/2010 Butterwolth ................ .. 396/155
2007/0004065 Al* 1/2007 Schardt er a1. ................ .. 438/26 2011/0031516 A1 2/2011 Basin et a1.
2007/0096131 Al* 5/2007 Chandra .. 257/99
2008/0048200 A1 2/2008 Mueller et a1. FOREIGN PATENT DOCUMENTS
2008/0079017 A1 4/2008 LOh et a1.
2008/0080165 Al* 4/2008 Kim et a1. ..................... .. 362/84 $8 ggig?gggg “@818
2008/0157103 A1 7/2008 Chandra
2009/0001372 A1 l/2009 Arik et a1. * cited by examiner
US. Patent Aug. 21, 2012 Sheet 1 0f 21 US 8,247,248 B2
32
Fig. 1A Fig. 15
32
US. Patent Aug. 21, 2012 Sheet 2 0f 21 US 8,247,248 B2
34
m
Fig. 2A
Fig. 2B
Fig. 2c
US. Patent Aug. 21, 2012 Sheet 3 0f 21 US 8,247,248 B2
32
32
8
31
5 I ‘l l'l
Fig. 3B
US. Patent Aug. 21, 2012 Sheet 4 0f 21 US 8,247,248 B2
Fig. 4A Fig. 4B
Fig 40 Fig. 4D
US. Patent Aug. 21, 2012 Sheet 5 or 21 US 8,247,248 B2
Fig. 5A Fig- 5B
Fig. 50 Fig. 5D
US. Patent Aug. 21, 2012 Sheet 6 0f 21 US 8,247,248 B2
Fig. 6F
US. Patent Aug. 21, 2012 Sheet 7 or 21 US 8,247,248 B2
Fig, 7
US. Patent Aug. 21, 2012 Sheet 8 0f 21 US 8,247,248 B2
Fig. 8A ' Fig. 8D
Fig. 8E
Fig. 88
Fig. 86
Fig. 8F
Fig. 8G