MATERIAL STACK FOR LEDS WITH A DOME
Various embodiments include methods for forming domed light-emitting diode (LED)-modules and devices constructed by those methods. In one example, the domed LED-module includes a package substrate, an LED die formed on the package substrate, one or more silicone pads formed on the package substrate and at least partially surrounding the LED die, and a high refractive-index material formed over the one or more silicone pads. Other devices and methods are described.
1 . A domed light-emitting diode (LED)-module, the domed LED-module comprising:
a package substrate;
an LED die formed on the package substrate;
one or more silicone pads formed on the package substrate and at least partially surrounding the LED die; and
a high refractive-index material formed over the one or more silicone pads.
2 . The domed LED-module of claim 1 , wherein the one or more silicone pads comprise at least one layer of methyl silicone.
3 . The domed LED-module of claim 1 , wherein the one or more silicone pads may comprise a plurality of layers.
4 . The domed LED-module of claim 1 , further comprising a colorant comprised of high refractive-index particles dispersed within the one or more silicone pads.
5 . The domed LED-module of claim 4 , wherein high refractive-index particles are selected from one or more particle types including titanium oxide, zinc oxide, aluminum oxide, and magnesium oxide.
6 . The domed LED-module of claim 1 , further comprising a cathode mount and an anode mount formed on the package substrate, the cathode mount and the anode mount being configured to electrically couple to the LED die.
7 . The domed LED-module of claim 1 , wherein the high refractive-index material comprises at least one layer of phenyl silicone.
8 . The domed LED-module of claim 1 , wherein the high refractive-index material is formed in to achieve a desired radiation-distribution pattern.
9 . The domed LED-module of claim 1 , wherein the high refractive-index material is formed to achieve a desired formed to focus radiation from the LED die in a desired direction.
10 . The domed LED-module of claim 1 , wherein the high refractive-index material is formed to achieve a desired formed to focus radiation from the LED die with a desired beam spread.
11 . The domed LED-module of claim 1 , wherein the high refractive-index material has a refractive index of greater than about 1.5.
12 . The domed LED-module of claim 1 , wherein the one or more silicone pads have a glass-transition temperature of at least less than about −40° C.
13 . A light-emitting diode (LED)-module, the LED-module comprising:
a package substrate;
an LED die formed on the package substrate;
one or more pads, comprising methyl silicone, formed on the package substrate and at least partially surrounding the LED die; and
a dome, comprising phenyl silicon, formed over the one or more silicone pads.
14 . The LED-module of claim 13 , further comprising a colorant comprised of high refractive-index particles dispersed within the one or more silicone pads.
15 . The LED-module of claim 13 , wherein the dome is formed in to achieve a desired radiation-distribution pattern.
16 . The LED-module of claim 13 , wherein the dome is formed to achieve a desired formed to focus radiation from the LED die in a desired direction.
17 . The LED-module of claim 13 , wherein the dome is formed to achieve a desired shape to focus radiation from the LED die with a desired beam spread.
18 . A method of forming a domed light-emitting diode (LED)-module, the method comprising:
mounting an LED die on a package substrate;
forming one or more silicone pads formed on the package substrate, the one or more silicone pads at least partially surrounding the LED die; and
forming a high refractive-index material formed over the one or more silicone pads.
19 . The method of claim 18 , wherein the high refractive-index material is compression-moulded over the one or more silicone pads.
20 . The method of claim 18 , wherein the one or more silicone pads are formed to a thickness of at least about 5 μm.