Method and apparatus for packaging phosphor-coated LEDs
View Patent ↗The present disclosure involves a method of packaging light-emitting diodes (LEDs). According to the method, a plurality of LEDs is provided over an adhesive tape. The adhesive tape is disposed on a substrate. In some embodiments, the substrate may be a glass substrate, a silicon substrate, a ceramic substrate, and a gallium nitride substrate. A phosphor layer is coated over the plurality of LEDs. The phosphor layer is then cured. The tape and the substrate are removed after the curing of the phosphor layer. A replacement tape is then attached to the plurality of LEDs. A dicing process is then performed to the plurality of LEDs after the substrate has been removed. The removed substrate may then be reused for a future LED packaging process.
1. A lighting apparatus, comprising:
a white light-emitting die that includes:
a first-type semiconductor layer;
a light emitting layer disposed over the first-type semiconductor layer;
a second-type semiconductor layer disposed over the light emitting layer;
a first conductive terminal electrically connected to the first-type semiconductor layer;
a second conductive terminals disposed on a surface of the second-type semiconductor layer; and
a phosphor film under which the first-type semiconductor layer, the light emitting layer, the second-type semiconductor layer, and the two conductive terminals are covered, wherein the phosphor film includes a first sub-layer and a second sub-layer disposed over the first sub-layer, and wherein the first sub-layer contains yellow phosphor particles mixed with a gel, and the second sub-layer contains red phosphor particles mixed with a gel.
2. The lighting apparatus of claim 1 , wherein the first sub-layer contains a gel mixed with phosphor particles, and the second sub-layer contains a gel mixed with diffuser particles.
3. The lighting apparatus of claim 1 , wherein the phosphor film has a convex dome-like shape.
4. The lighting apparatus of claim 1 , wherein the phosphor film has one of the following shapes: a concave V-shape, a concave U-shape, or a concave W-shape.
5. The lighting apparatus of claim 4 , further comprising a reflective layer disposed over the phosphor film.
6. The lighting apparatus of claim 1 , wherein a refractive index of the phosphor film is in a range from about 1.4 to about 2.0.
7. The lighting apparatus of claim 1 , further comprising: a supporting member on which a plurality of the white light-emitting dies are located.
8. The lighting apparatus of claim 7 , further comprising a housing inside which the supporting member and the plurality of white light-emitting dies are located.
9. The lighting apparatus of claim 8 , wherein the housing is configured for one of: a light bulb, a light tube, a par light, and a down light.
10. The lighting apparatus of claim 7 , wherein the plurality of white light-emitting dies are arranged in a row.
11. The lighting apparatus of claim 7 , wherein the plurality of white light-emitting dies are arranged in matrix.
12. A lighting apparatus, comprising:
a light-emitting diode (LED) that includes:
a first-type semiconductor layer;
a light emitting layer disposed over the first-type semiconductor layer; and
a second-type semiconductor layer disposed over the light emitting layer, the first-type semiconductor layer and the second-type semiconductor layer having different types of conductivity;
a phosphor film coated around the LED, wherein the phosphor film includes a first sub-layer and a second sub-layer disposed over the first sub-layer, wherein the first sub-layer contains a gel mixed with phosphor particles, wherein the second sub-layer contains a gel mixed with diffuser particles or a gel mixed with different phosphor particles than the first sub-ayer, and wherein the phosphor film has one of the following shapes: a convex dome-like shape, a concave V-shape, a concave U-shape, or a concave W-shape; and
a reflective layer disposed over the phosphor film.
13. The lighting apparatus of claim 12 , further comprising:
a plurality of LEDs that each have a phosphor film coated thereon;
a supporting member on which the plurality of LEDs is located; and
a housing that houses the supporting member and the plurality of LEDs within.
14. The lighting apparatus of claim 13 , wherein:
the housing is configured for one of: a light bulb, a light tube, a par light, and a down light; and
the plurality of LEDs is arranged in a row or in a matrix.
15. The lighting apparatus of claim 12 , wherein the LED includes a first conductive terminal electrically connected to the first-type semiconductor layer and a second conductive terminal disposed on a surface of the second-type semiconductor layer.
16. The lighting apparatus of claim 12 , wherein the diffuser particles include silica, PMMA, ZrO 2 , or silicon.
17. A lighting apparatus, comprising:
a plurality of light-emitting diodes (LEDs), wherein each LED includes:
a first-type semiconductor layer;
a light emitting layer disposed over the first-type semiconductor layer;
a second-type semiconductor layer disposed over the light emitting layer;
a phosphor film conformally coated on an upper surface and side surfaces of the LED; and
a reflective layer disposed over the phosphor film,
a supporting member on which the plurality of LEDs is located; and
an encapsulation structure that houses the supporting member and the plurality of LEDs therein;
wherein:
the phosphor film has one of the following shapes: a convex dome-like shape, a concave V-shape, a concave U-shape, or a concave W-shape;
the phosphor film includes a first sub-layer and a second sub-layer disposed over the first sub-layer;
the first sub-layer contains a gel mixed with phosphor particles; and
the second sub-layer contains a gel mixed with diffuser particles or a gel mixed with phosphor particles different from those within the first sub-layer.
18. The lighting apparatus of claim 17 , wherein: the housing is configured for one of: a light bulb, a light tube, a par light, and a down light.
19. The lighting apparatus of claim 17 , wherein the plurality of LEDs are arranged in a row or in a matrix.
20. The lighting apparatus of claim 18 , wherein the diffuser particles include silica, PMMA, ZrO 2 , or silicon.