Patent ID: 11973169
Assignee: LUMILEDS, LLC
Field: Semiconductors (Electrical engineering)
Classification: CPC H  G | IPC G  H

Claim 0:
1. A method comprising:
providing, on a release film, a bi-layer wavelength converting layer comprising a phosphor layer and an optical material layer, by coating the phosphor layer and the optical material layer on the release film;
after providing the bi-layer wavelength converting layer on the release film, laminating the phosphor layer and the optical material layer together to form a laminated bi-layer wavelength converting layer;
after forming the laminated bi-layer wavelength converting layer, disposing the laminated bi-layer wavelength converting layer on a tape;
after disposing the laminated bi-layer wavelength converting layer on a tape, cutting the laminated bi-layer wavelength converting layer on the tape to create gaps of a first spacing in the laminated bi-layer wavelength converting layer such that the laminated bi-layer wavelength converting layer forms a plurality of bi-layer wavelength layer converting elements in an array pattern, the bi-layer wavelength converting layer elements including the phosphor layer and the optical material layer in the array pattern;
inserting an unfilled wafer mesh having an array of cavities separated by intersecting cavity walls into the gaps of the first spacing to form a wafer mesh surrounding bi-layer wavelength converting layer elements and covering sidewalls of the phosphor layer and sidewalls of the optical material layer;
providing an array of semiconductor light emitting devices (LED array) having a plurality of light emitting devices spaced apart from each other at a second spacing greater than the first spacing;
positioning the wafer mesh relative to the LED array so that each of the light emitting devices of the LED array is aligned with a bi-layer wavelength converting layer element surrounded by the wafer mesh;
after positioning the wafer mesh with the LED array, attaching each of the light emitting devices to the aligned bi-layer wavelength converting layer element so that the phosphor layer is between the optical material layer and the light emitting device, and
removing at least some of the wafer mesh.