Source: http://www.google.fr/patents/US8167674?hl=fr
Timestamp: 2017-03-29 09:19:31
Document Index: 727392186

Matched Legal Cases: ['application No. 08', 'Application No. 08171399', 'Application No. 05808825', 'Application No. 2006', 'Application No. 2006', 'Application No. 2009', 'Application No. 2009', 'Application No. 10', 'Application No. 093128231', 'Application No. 200780050127', 'Application No. 05808825']

Brevet US8167674 - Phosphor distribution in LED lamps using centrifugal force - Google BrevetsRecherche Images Maps Play YouTube Actualités Gmail Drive Plus »Connexion BrevetsA method of manufacturing an LED lamp is disclosed. The method includes admixing an uncured curable liquid resin and a phosphor, dispensing the uncured admixture on an LED chip, centrifuging the chip and the admixture to disperse the phosphor particles in the uncured resin, and curing the resin while...http://www.google.fr/patents/US8167674?utm_source=gb-gplus-shareBrevet US8167674 - Phosphor distribution in LED lamps using centrifugal force Recherche avancée dans les brevetsTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents. Numéro de publicationUS8167674 B2Type de publicationOctroi Numéro de demandeUS 11/956,989 Date de publication1 mai 2012 Date de dépôt14 déc. 2007 Date de priorité14 déc. 2007État de paiement des fraisPayéAutre référence de publicationEP2071636A1, EP2071636B1, US20090153022 Numéro de publication11956989, 956989, US 8167674 B2, US 8167674B2, US-B2-8167674, US8167674 B2, US8167674B2 InventeursChristopher P. Hussell, David T. Emerson Cessionnaire d'origineCree, Inc.Exporter la citationBiBTeX, EndNote, RefManCitations de brevets (163), Citations hors brevets (63), Référencé par (21), Classifications (15), Événements juridiques (2) Liens externes: USPTO, Cession USPTO, EspacenetPhosphor distribution in LED lamps using centrifugal force
US 8167674 B2 Résumé
The present invention relates to light emitting diodes and diode lamps in which a phosphor is used to absorb and modify the primary emission from the diode. In particular, the invention relates to light emitting diodes that emit in the blue, violet, and ultraviolet (UV) portions of the electromagnetic spectrum used in conjunction with an encapsulant package that contains a phosphor that down-converts the frequencies emitted by the diode into light with a strong yellow component to produce a combined output of white light.
Accordingly, the term “diode” or “chip” typically refers to the structure that minimally includes two semiconductor portions of opposite conductivity types (p and n) along with some form of ohmic contacts through which electric current is applied to the resulting p-n junction.
As used herein, the term “package” typically refers to the placement of the semiconductor chip on an appropriate physical and electrical structure (sometimes as simple as a small piece of metal through which the electrical current is applied) along with a lens that provides some physical protection to the diode and can optically direct the light output. Lenses are often formed of transparent polymers and in some cases the same polymer forms an encapsulant for the diode. In the present context, the package includes a reflective structure, frequently formed of a metal or polymer within which the diode rests. Adding a lens and electrical contacts typically forms a lamp.
As the availability of blue-emitting LEDs has greatly increased, the use of yellow-emitting phosphors that down-convert the blue photons has likewise increased. Specifically, the combination of the blue light emitted by the diode and the yellow light emitted by the phosphor can create white light. In turn, the availability of white light from solid-state sources provides the capability to incorporate them in a number of applications, particularly including illumination and as lighting (frequently backlighting) for color displays. In such devices (e.g., flat computer screens, personal digital assistants, and cell phones), the blue LED and yellow phosphor produce white light which is then distributed in some fashion to illuminate the color pixels. Such color pixels are often formed by a combination of liquid crystal elements, color filters and polarizers, and the entire unit including the backlighting is generally referred to as a liquid crystal display. (“LCD”).
In order to deal with these difficulties, most conventional techniques attempt to maintain the viscosity of the uncured resin within a range that permits the phosphor to settle within the encapsulant under the influence of gravity. This in turn requires controlling the length of time (“working time”) during which the resin will cure—the phosphor should reach the desired position(s) before the resin cures—as well as the temperature in an effort to maintain a favorable viscosity while the phosphor is settling. For example, at room temperature (25° C.), a typical 2-part silicon resin (e.g. SR-7010 from Dow Corning) will normally cure in about one minute at 150° C. and its viscosity will double (from respective starting points of about 20000 and 7000 millipascal for the parts) in about three (3) hours at room temperature.
In one aspect the invention is a method of manufacturing an LED lamp comprising admixing an uncured curable liquid resin and a phosphor, dispensing the uncured admixture on an LED chip, centrifuging the chip and the admixture to settle or deposit the phosphor particles in the uncured resin, and curing the resin while the phosphor particles remain distributed at or near the desired positions.
FIG. 1 is a perspective view of a light emitting diode lamp of the type manufactured using the method of the present invention.
The invention is a method of manufacturing a light emitting diode (LED) lamp. The method comprises admixing an uncured curable liquid resin and a phosphor, dispensing the uncured admixture on an LED chip, centrifuging (or otherwise exerting centrifugal force on) the chip and the admixture to position the phosphor particles in the uncured resin, and then curing the resin while the phosphor particles remain positioned on or near the desired surface of the diode.
As used herein, the phrase “uncured curable liquid resin” typically refers to a polymer resin that has not yet become cross-linked (e.g. thermosetting resins), or solidified based on temperature (thermoplastic resins). Thus, in some cases the uncured resin is a liquid at room temperature that will cross-link under the influence of heat, or time or (in some cases) ultraviolet light. In other cases, the uncured resin is a liquid at elevated temperatures and will solidify at temperatures approaching room temperature.
The resin (sometimes referred to as the “encapsulant”) can be any material that is suitable for the purposes of the invention and that does not otherwise interfere with the operation of the LED chip or the other elements of the lamp. The term “resin” is used in a broad sense to refer to any polymer, copolymer or composite from which the package can be formed. These materials are generally well understood by those of ordinary skill in the art and need not be discussed in detail.
As set forth in co-pending and commonly assigned application Ser. No. 60/824,385 filed Sep. 1, 2006 for “Phosphor Position In Light Emitting Diodes,” when the LED chip emits in the higher energy portions of the spectrum (e.g., blue, violet, and ultraviolet), the encapsulant should be less reactive or inert to the photons emitted at such frequencies. Thus, the polysiloxane (“silicone”) resins tend to be particularly well suited for the encapsulant. In general, the term polysiloxane refers to any polymer constructed on a backbone of —(—Si—O—)n— (typically with organic side groups). The polysiloxane resins offer greater stability with respect to higher frequency emissions as compared to the photostability of otherwise functionally similar materials such as polycarbonate or polyester resins (both of which may be acceptable in certain contexts). Polysiloxane resins also have high optical clarity, can be favorably elastomeric, and are less affected by thermal cycling than are some other polymers. They can be formulated with a range of refractive indices (1.40 to 1.58), a factor that can be used to reduce interfacial losses and enhance a lamp's external output. Viscosities of polysiloxane resins can range about 7000 to 20,000 millipascal-seconds, and the invention can be carried out with resins (or other liquids) having viscosities of less than 10 and up to 100,000 millipascal-seconds
The phosphor particles are selected to produce or enhance a given chip emission and to suit or enhance a particular application. In many cases, the phosphor is selected from among those materials that down-convert frequencies in the blue portion of the visible spectrum into frequencies in the yellow portion of the visible spectrum. Again, those persons skilled in this art will recognize that the phosphor need not emit exclusively in the yellow portion of the spectrum, but that a predominant emission in the yellow portion is helpful because the combination of blue light from the diode chips and yellow frequencies from the phosphor produces the desired white light. Again, the boundaries are somewhat arbitrary, but the yellow frequencies are generally in the 550-600 nanometer range with 570 nanometers being representative. In other embodiments, red-emitting, green-emitting and in some cases even blue-emitting phosphors can be added to produce a “warmer” white or to achieve a higher color rendering Index (CRI).
Depending upon the nature and amount of the phosphor, the combination of the chip and phosphor can produce “cool white” light with a color temperature of between about 5000 and 10,000 K, or “neutral white” (3700-5000 K) or “warm white” (2600-3700 K). The term “color temperature” is used in its well-understood sense to represent the temperature to which a theoretical “black body” would be heated to produce light of the same visual color.
One of the phosphors most useful for purposes of the invention is the yttrium aluminum garnet (“YAG”), typically doped with cerium. Other garnet structures that emit in the yellow region are known in the art (e.g., U.S. Pat. No. 6,669,866). White light can also be produced using LEDs that emit in the near-ultraviolet portion of the spectrum with combinations of red, blue and green emitting phosphors. For example, europium-doped strontium gallium sulfide (SrGa2S4:Eu) emits in the green portion of the spectrum while cerium-doped gadolinium aluminum oxide (Gd3Al5O12:Ce) is excited at frequencies of about 470 nanometers and emits in the orange portion (about 525-620 nm) of the spectrum. Zinc sulfide doped with copper also emits in the green portion of the spectrum. Europium-doped nitridosilicates can emit in the yellow to red portion of the spectrum (e.g., U.S. Pat. No. 6,649,946).
As a formal detail, those familiar with the laws of motion will recognize that “centrifugal force” is sometimes referred to as a “pseudo-force” because it actually represents the combination of the momentum of an object moving in a circular path against the centripetal force holding the rotating object in position with respect to a center of rotation. Similarly, when used as a noun, the term “centrifuge” defines a machine using centrifugal force for separating substances of different densities, for removing moisture, or for simulating gravitational effects. When used as a verb, “centrifuge” defines the act of applying a centrifugal force in order to separate solids from liquids, or different layers in a liquid or to otherwise simulate and increase gravitational effects.
FIG. 4 is a schematic cross-sectional view of a side view diode (side mount, sidelooker, surface mount device (“SMD”)) broadly designated at 25. The diode chip is again illustrated at 11 and the phosphor particles at 13. In this embodiment the reflector package 18 is often formed of a white polymer. If viewed from a top plan orientation, the package 18 can be round, rectangular or square in shape. Because an SMD such as the one illustrated at 25 is often positioned adjacent a light diffuser or in a similar orientation, the encapsulant 19 has a flat, nearly-flat, or concave profile and does not include the spherical lens illustrated in FIGS. 1-3. As FIG. 4 illustrates, the diode 11 can be positioned directly on one of the electrodes 26 or can be connected to the electrodes 26 and 27 using the wires 28 and 29.
FIG. 5 is a top plan view of portions of a centrifuge of the type referred to previously. A rotor 40 defines a center of rotation and is typically driven by a motor (not shown). Four arms 41 extend from the rotor 40 and in the illustrated embodiment include the L-shaped extensions 42 that define respective positions at which four trays 43 can be attached using the pins schematically illustrated at 44. A direction of rotation is indicated by the arrow “R”. When the centrifuge is at rest, diodes can be placed into the squares 45 in the trays 43 (or pre-loaded trays can be attached to the pins 44). In particular, the trays 43 can be designed with squares or other appropriate structures that match the size and shape of the diodes being centrifuged.
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