Patent ID: 8338199
Filing Date: 2012-12-25
Classification: H01L,H01S

Abstract:
1. A method for fabricating a lighting device comprising: depositing a plurality of electrodes on a top surface of a first substrate; forming conductors on a bottom surface of the first substrate opposite the top surface where the plurality of electrodes are deposited, the conductors being arranged to interconnect at least a portion of the plurality of electrodes through openings in the first substrate; providing a plurality of light emitting diode (LED) dies, each LED die having an anode and a cathode formed on a same surface of the LED die; affixing each LED die to the top surface of the first substrate to contact the cathode and anode of each LED die with an associated pair of electrodes from among the plurality of electrodes such that the plurality of LED dies are electrically interconnected; forming metal vias extending through the first substrate, such that the LED dies are thermally coupled to the metal vias for sinking heat from the LED dies; providing an intermediate sheet of a thickness approximately equal to a thickness of each LED die of the plurality of LED dies, the intermediate sheet comprising applying the intermediate sheet over the top surface of the first substrate; encapsulating each LED die by filling each hole with an encapsulant; applying a transparent second substrate over the intermediate sheet; and forming a plurality of tiles on the second substrate over corresponding plurality of LED dies, wherein at least one of the encapsulant and the plurality of tiles include a wavelength conversion material for generating white light.