Packaged light emitting diodes including phosphor coating and phosphor coating systems
View Patent ↗Light emitting structures are disclosed that can include a semiconductor light emitting diode (LED) that includes a p-n junction active layer. A first layer can include a binder material having a thickness that is less than about 1000 μm, wherein the first layer is directly on the LED. A second layer can include phosphor particles, where the second layer can have a thickness that is less than about 1000 μm and can be directly on the first layer so that the first layer is between the LED and the second layer.
1. A light emitting structure, comprising:
a semiconductor light emitting diode (LED) comprising a p-n junction active layer;
a first layer comprising binder material having a thickness less than about 1000 μm directly on the LED;
a second layer comprising phosphor particles and having a thickness less than about 1000 μm, the second layer directly on the first layer so that the first layer is between the LED and the second layer; and
a third layer on the second layer, the third layer comprising diffuser particles.
2. The light emitting structure of claim 1 , wherein the first layer comprises a binder layer sprayed directly on the LED and the second layer comprises a phosphor layer sprayed directly on the binder layer.
3. The light emitting structure of claim 1 , wherein the first layer is thicker than the second layer.
4. The light emitting structure of claim 1 , wherein the first layer has a thickness that is about 100 times a thickness of the second layer.
5. The light emitting structure of claim 1 , wherein the first layer and the second layer have about a same thickness.
6. The light emitting structure of claim 1 , further comprising:
a fourth layer comprising phosphor particles having a thickness less than about 1000 μm directly on the first layer of binder material.
7. The light emitting structure of claim 1 , wherein the semiconductor light emitting diode comprises an LED wafer.
8. The light emitting structure of claim 1 , wherein the semiconductor light emitting diode comprises an LED chip.
9. The light emitting structure of claim 1 , wherein the phosphor particles comprises first phosphor particles configured to emit light at a first dominant wavelength, the structure further comprising:
a fourth layer on the second layer and having a thickness less than about 1000 μm, the fourth layer comprising second phosphor particles configured to emit light at a second dominant wavelength.
10. The light emitting structure of claim 9 , wherein the first dominant wavelength is the same as the second dominant wavelength.
11. The light emitting structure of claim 9 , wherein the first dominant wavelength is different from the second dominant wavelength.
12. The light emitting structure of claim 1 , wherein the phosphor particles comprises first phosphor particles configured to emit light at a first dominant wavelength, the structure further comprising:
a fourth layer on the second layer and having a thickness less than about 1000 μm, the fourth layer comprising second phosphor particles configured to emit light at a second dominant wavelength.
13. The light emitting structure of claim 1 , wherein the first layer is directly on an upper surface of the LED that is opposite a surface of a substrate beneath the LED.
14. The light emitting structure of claim 1 , wherein the first layer is directly on an upper surface of the LED that is opposite a surface of a substrate beneath the LED.
15. The light emitting structure of claim 1 , wherein the binder material comprises silicone and/or epoxy.
16. A light emitting structure, comprising:
a semiconductor light emitting diode (LED) comprising a p-n junction active layer;
a first layer comprising binder material and having a thickness less than about 1000 μm, wherein the first layer is directly on the LED;
a second layer comprising phosphor particles, the second layer having a thickness less than about 1000 μm and being directly on the first layer so that the first layer is between the LED and the second layer;
a third layer of binder material directly on the second layer; and
a fourth layer including light diffuser particles on the third layer.