Fan-out light-emitting diode (LED) device substrate with embedded backplane, lighting system and method of manufacture

1. A method comprising:

forming a first cavity in a substrate;

placing a backplane in the first cavity;

forming at least one layer of dielectric material over the substrate and the backplane;

forming a second cavity in the at least one layer of the dielectric material to expose at least a portion of a surface of the backplane;

placing a metal slug in the second cavity and in contact with the at least the portion of the surface of the backplane;

forming a plurality of vias in the at least one layer of dielectric material;

providing an electrically conductive material in the plurality of vias to form an array of electrically conductive structures electrically coupled to the backplane; and

electrically coupling a plurality of light-emitting diode (LED) arrays to at least some of the electrically conductive structures.

2. The method of claim 1 , further comprising forming conductive pads on the plurality of vias.

3. The method of claim 2 , further comprising forming metal pillars on the conductive pads.

4. The method of claim 3 , further comprising forming solder bumps on the metal pillars.

5. The method of claim 4 , further comprising aligning an LED array with the solder bumps on the metal pillars.

6. The method of claim 5 , further comprising applying heat to at least the solder bumps to reflow the solder bumps and electrically couple individual emitters in the LED array to individual ones of the solder bumps.

7. The method of claim 1 , further comprising placing the substrate on a tape prior to placing the backplane in the first cavity.

8. The method of claim 7 , wherein the placing the backplane in the first cavity further comprises coupling the backplane to the tape.

9. The method of claim 1 , further comprising plating at least one surface of the substrate.

10. The method of claim 9 , wherein the plating further comprises plating inner surfaces of the vias.

11. The method of claim 10 , wherein the forming the at least one layer of the dielectric material over the substrate and the backplane further comprises forming the at least one layer of the dielectric material over a first surface of the substrate and a first surface of the backplane.

12. The method of claim 11 , further comprising forming at least one additional layer of the dielectric material over a second surface of the substrate and the backplane that is opposite the first surface.

13. The method of claim 12 , further comprising forming at least one via in the dielectric material and exposing at least a portion of the plating.

14. The method of claim 13 , further comprising forming at least one conductive pad over the at least one via on an outer surface of the dielectric material.

15. A method comprising:

forming a first cavity in a substrate;

placing a backplane in the first cavity;

forming at least one layer of dielectric material over the substrate and the backplane;

forming a second cavity in the at least one layer of the dielectric material to expose at least a portion of a surface of the backplane;

placing a metal slug in the second cavity and in contact with the at least the portion of the surface of the backplane;

forming at least one other first cavity in the substrate;

placing at least one other backplane in the at least one other first cavity in the substrate;

forming at least one other second cavity in the at least one layer of the dielectric material to expose at least a portion of a surface of the at least one other backplane; and

placing at least one other metal slug in the at least one other second cavity and in contact with the at least the portion of the surface of the at least one other backplane.

16. The method of claim 15 , further comprising:

forming at least one other plurality of vias in the at least one layer of dielectric material and filling the plurality of vias with an electrically conductive material to form at least one other array of electrically conductive structures electrically coupled to the at least one other backplane; and

electrically coupling at least one other LED array to the at least one other array of electrically conductive structures electrically coupled to the at least one other backplane.

17. The method of claim 16 , further comprising dicing the substrate to form a plurality of LED lighting systems.