Source: https://patents.google.com/patent/US9431589B2/en
Timestamp: 2019-06-25 09:03:11
Document Index: 13347333

Matched Legal Cases: ['Application No. 2007', 'Application No. 2008', 'Application No. 2006', 'Application No. 2006', 'Application No. 2007', 'Application No. 2008', 'Application No. 200810186835', 'Application No. 04788908', 'Application No 2009', 'Application No. 2008', 'Application No. 20110', 'Application No. 2008', 'Application No. 2009', 'Application No. 2008', 'Application No. 2011', 'Application No. 2011', 'Application No. 093112133', 'Application No. 2006', 'Application No. 4867', 'Application No. 200910137491', 'Application No. 200810186835', 'Application No. 2007', 'Application No. 200910137491']

US9431589B2 - Textured encapsulant surface in LED packages - Google Patents
Textured encapsulant surface in LED packages Download PDF
US9431589B2
US9431589B2 US12/002,429 US242907A US9431589B2 US 9431589 B2 US9431589 B2 US 9431589B2 US 242907 A US242907 A US 242907A US 9431589 B2 US9431589 B2 US 9431589B2
US12/002,429
US20090152573A1 (en
Ernest W. Combs
2007-12-14 Application filed by Cree Inc filed Critical Cree Inc
2007-12-14 Priority to US12/002,429 priority Critical patent/US9431589B2/en
2008-02-04 Assigned to CREE, INC. reassignment CREE, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: COMBS, ERNEST W., YOU, CHENHUA, CANNON, NATHANIEL O., JACKSON, MITCH, KELLER, BERND, LOH, BAN P.
2008-05-14 Assigned to CREE, INC. reassignment CREE, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: COMBS, ERNEST W., YOU, CHENHUA, CANNON, NATHANIEL O., JACKSON, MITCH, KELLER, BERND, LOH, BAN P.
2009-06-18 Publication of US20090152573A1 publication Critical patent/US20090152573A1/en
2016-08-30 Publication of US9431589B2 publication Critical patent/US9431589B2/en
A packaged LED device having a textured encapsulant that is conformal with a mount surface on which at least one LED chip is disposed. The textured encapsulant, which can be textured using an additive or subtractive process, is applied to the LED either prior to or during packaging. The encapsulant includes at least one textured surface from which light is emitted. The textured surface helps to reduce total internal reflection within the encapsulant, improving the extraction efficiency and the color temperature uniformity of the output profile. Several chips can be mounted beneath a single textured encapsulant. A mold having irregular surfaces can be used to form multiple encapsulants over many LEDs simultaneously.
The invention relates generally to LED packages and, more particularly, to textured encapsulant surfaces within the LED packages.
LED packages typically have some type of encapsulant surrounding the LED chip to enhance light extraction from the chip and protect the chip and related contacts structure (e.g., wire bonds) from exposure to physical damage or environmental conditions which could lead to corrosion or degradation. Along with this encapsulant, an optical element such as a simple hemispherical lens is also desired to enhance light extraction from the package and possibly to provide some form of output light beam shaping (control over the angle-dependent emission properties of the lamp). For surface mount packages, which typically require high temperature (200-300° C.) solder reflow processing to attach the LED package to its final fixture, the possible materials typically include silicones and glasses. Silicone lenses are typically molded using injection molding processes, which can place limitations on the properties of the silicone that may be used. Glass lenses are typically formed using a melting process that can limit the possible geometries and add substantial piece part cost to the final lamp. Typical wire bonded LEDs cannot be encapsulated in molten glass because of the high melting temperature of glass.
The efficient extraction of light from LEDs is a major concern in the fabrication of high efficiency LEDs. For conventional LEDs with a single out-coupling surface, the external quantum efficiency is limited by total internal reflection (TIR) of light from the LED's emission region that passes through the substrate. TIR can be caused by the large difference in the refractive index between the LED's semiconductor and surrounding ambient. Some LEDs have relatively low light extraction efficiencies because the high index of refraction of the substrate compared to the index of refraction for the surrounding material, such as epoxy. This difference results in a small escape cone from which light rays from the active area can transmit from the substrate into the epoxy and ultimately escape from the LED package.
U.S. Pat. No. 6,657,236, also assigned to Cree Inc., discloses structures formed on the semiconductor layers for enhancing light extraction in LEDs through the use of internal and external optical elements formed in an array. The optical elements have many different shapes, such as hemispheres and pyramids, and may be located on the surface of, or within, various layers of the LED. The elements provide surfaces from which light refracts or scatters.
In order to emit light having a specific spectral content, it is known to use LED packages having multiple chips. Often, multiple chips having different colors are used in the same package. For example, a red chip, a green chip and a blue chip can be used in combination to form a white light package (solid state RGB). Other multi-chip combinations are also common, such as the solid state RGGB which comprises one red chip, one blue chip and two green chips per unit. Phosphor conversion layers may be used in conjunction with these multi-chip devices, for example, the phosphor converted RGB which is used for high Color Rendering Index applications. Another known device consists of a phosphor converted white LED and a solid state red chip. Other combinations of phosphor-converted colored chips and solid state chips are also known in a multi-chip LED package.
One embodiment of a light emitting diode (LED) device comprises the following elements. At least one LED chip is disposed on a mount surface. An encapsulant is disposed proximate to the mount surface such that substantially all of the light emitted from the at least one LED passes through the encapsulant. The encapsulant comprises a textured emission surface that is substantially conformal with the mount surface. The encapsulant reduces the total internal reflection of the emitted light as compared to a similar encapsulant having a non-textured emission surface.
One embodiment of a chip-scale package light emitting diode (LED) device comprises the following elements. A plurality of LEDs is disposed on a mount surface. An encapsulant has an emission surface that is substantially parallel to the mount surface. The emission surface is textured to create a plurality of roughening surface features.
One method of fabricating a light emitting diode (LED) device comprises the following actions. A mount surface is provided. At least one LED chip is disposed on the mount surface. An encapsulant having an emission surface is deposited on the at least one LED chip. The encapsulant is shaped such that the emission surface is textured. The encapsulant is cured.
FIG. 1 shows a cross-sectional view of an embodiment of an LED device.
FIG. 2 shows a cross-sectional view of an embodiment of an LED device.
FIG. 3 shows a top plan view of an LED device having red, green and blue LED chips.
FIG. 4 shows a top plan view of an LED device having several reg, green and blue LED chips.
FIG. 5 shows a top plan view of an embodiment of a mold device for simultaneously molding several encapsulants on LED devices.
FIG. 6 shows a cross-sectional view of an embodiment of a cavity in a portion of a mold device.
FIG. 7 shows a cross-sectional view of an embodiment of a cavity in a portion of a mold device.
FIG. 8 shows a cross-sectional view of an embodiment of an LED package device 800.
The present invention provides embodiments of an LED device comprising an encapsulant with a textured surface that helps to reduce light loss due to total internal reflection (TIR) while maintaining acceptable color temperature uniformity and color mixing in the output profile. TIR is an optical phenomenon that occurs when a ray of light strikes a medium boundary at an angle that exceeds the critical angle as defined by Snell's Law. The critical angle is a function of the index of refraction differential between the two media. TIR can only occur when light passes from a medium with a higher index of refraction to a medium with a lower index of refraction. If a light ray strikes the medium boundary at an angle greater than the critical angle, the light will reflect back into the medium from which it came rather than escaping as emitted light. The internally reflected light may then be absorbed by materials within the medium or by the medium itself. TIR reduces the extraction efficiency of an LED device.
Encapsulants can formed into many shapes to achieve various design goals. Some LED packages include a dome-shaped encapsulant disposed over the chip to reduce the TIR of the emitted light. The dome-shaped encapsulant may be designed so that the light rays are incident on the inner surface of the encapsulant at close to right angles at all points of incidence. The geometry of these encapsulants ensures that light almost always strikes the boundary at close to a right angle; thus, the light is rarely reflected back into the encapsulant, yielding higher extraction efficiencies.
However, it is not always desirable to use a dome-shaped encapsulant. For example, in multi-chip arrangements it may not be acceptable to assume that the light is emanating from a point at the center of the mount surface on which the chips are disposed. The chips may be mounted in various positions on the mount surface. In many cases, the chips emit light of different colors. Because of the chip placement on the mount surface, each of the colored beams will have different angular distributions, and the emission spectrum will suffer from poor color uniformity in the output profile. Thus, a dome-shaped encapsulant reduces the effects of TIR but can lead to poor color mixing in multi-chip configurations.
A flat encapsulant, on the other hand, will provide a relatively uniform color distribution in the far field. However, the flat encapsulant will suffer from significant TIR, reducing the extraction efficiency of the device. This is especially true for interfaces having a refractive index differential of greater than 0.4, such as epoxy/air, silicone/air or any transparent plastic/air interface, for example. Embodiments of the present invention comprise an encapsulant having a modified surface to reduce the effects of TIR while maintaining relatively uniform color distribution.
FIG. 1 shows a cross-sectional view of an LED device 100 according to an embodiment of the present invention. The device 100 comprises an encapsulant element 102 that is disposed above the light sources 104 such that substantially all of the light emitted from the sources 104 has to pass through it.
The encapsulant 102 may be very thin such that it barely covers the bond wires, if they are used, or it can be much thicker. An acceptable range for the thickness of the encapsulant is 70-200 micrometers. The ray paths of the emitted light are shown by the arrows in the figures. In this embodiment, the encapsulant 102 is disposed such that the encapsulant 102 and the light sources 104 are mounted to a common surface 106, such as a substrate, for example.
The encapsulant 102 may comprise any structure that is disposed above the sources 104 as described above, and in one embodiment the encapsulant comprises a lens used alone or in combination with other bonding materials to mount the lens over the source. The encapsulant can be transparent, translucent, or luminescent, for example, and can be loaded with wavelength conversion materials, such as phosphors. The encapsulant 102 can be made of silicone, epoxy, glass, plastic or other materials and may perform functions such as beam shaping, collimating, and focusing, etc. The encapsulant 102 may be formed in place over the source as with a mold, or it may be fabricated separately and then subsequently attached to the light source by an adhesive epoxy, for example.
One way to redirect light is to modify selected areas of the encapsulant surface 108. The surface 108 can be modified by several known additive and subtractive methods such as etching or grinding, for example, as discussed in detail below. A textured surface can be produced by any known mass-production method such as molding or casting where the mold surface impresses the texturing contours directly on the encapsulant during the process. Light approaching a modified portion of the encapsulant surface 108 (as opposed to an unmodified portion) has a higher probability of being redirected and exiting the encapsulant 102 at another point. If the light does not exit on the first pass, it may be reflected within the encapsulant 102 and come in contact with the surface 108 again and be emitted on a second pass. The modified surface 108 also has the effect of randomizing the emission angle of the emitted light. As shown in FIG. 1, the irregular features of the modified surface 108 redirect the light, causing it to deviate from the path it originally took from the source 104. Because the light is disassociated from its original path, the output profile exhibits a more uniform color distribution.
The modified surface can be formed by additive or subtractive processes and may have features with many different shapes. For example, material may be added to the encapsulant surface to create irregular structures that will scatter the light. The added material may be deposited by many known processes such as chemical vapor deposition. A textured surface can also be fashioned using a post-additive process such as chemical etching, machining by single or multiple-point tools, sand-blasting, etc. Another method for modifying the surface is to remove portions of the encapsulant material leaving behind small holes and trenches. Many different known subtractive methods are available such as etching, for example. The modified surface can have patterned or random features. In the former case, it may be created by machining to give the surface a specifically patterned texture. If the surface is machined, an acceptable range of the average peak-to-valley size of the surface features would be from 50-200 micrometers. If the surface features are random, they may be formed by several processes including electro-discharge machining. Surface modifications may result in surface features that have several shapes including, spheres or hemispheres, triangles, skewed triangles, pyramids, truncated pyramids and many other shapes. There are many other known methods of modifying an encapsulant surface.
FIG. 2 is a cross-sectional illustration of an LED device 200 according to an embodiment of the present invention. The device 200 functions similarly as the device 100 and shares several common elements. The device 200 comprises a reflective surface 202. As discussed above the modified surface 108 also helps reduce TIR on light interacting with the surface 108 on second, third, etc., passes. The reflective surface 202 can comprise a diffuse reflector, a specular reflector, or a combination of the two. The reflective surface 202 should be highly reflective in the wavelength ranges emitted by the sources 104 for high efficiency. The reflective surface 202 can be specular or textured and can have scattering properties.
FIG. 3 is a top view of an LED device 300. The LED device 300 comprises a red chip 302, a green chip 304, and a blue chip 306, all of which are disposed on a mount surface. This embodiment shows one possible arrangement of chips in an RGB configuration. RGB chips may be arranged in many ways and are not restricted to any particular pattern. Because the chips 302, 304, 306 are not centered on the mount surface, the various colors of light are not emitted into the encapsulant 308 uniformly. For example, if the encapsulant 308 is flat (as shown), the light emitted from the red chip 302 will be incident on the portion of the encapsulant 308 directly above the red chip 302 at angles close to 90°. Whereas light emitted from the blue chip 306 will be incident on that same portion of the encapsulant 308 at much lower angles. Thus, if a randomization element is not used, more red light will be emitted in the space directly above the red chip 302 than blue light, leading to a poor color temperature uniformity in the output profile.
The LED device 300 comprises an encapsulant 308 having a textured surface 310. The encapsulant 308 is disposed such that the light emitted from the chips 302, 304, 306 passes through the encapsulant 308 and into the ambient space. The textured surface 310 improves extraction efficiency by reducing TIR and improves color temperature uniformity by randomizing the emission angle of light rays emitted from the various chips 302, 304, 306. Although this particular embodiment features an RGB chip configuration on a circular mount surface, it is understood that many different colored LED combinations may be used on many different shapes of mount surfaces.
FIG. 4 is a top plan view of another LED device 400. The device 400 includes several colored LED chips 402 disposed on a rectangular mount surface. This particular embodiment features an RGGB arrangement of red, green and blue emitters. As discussed above many different color and spatial arrangements may be used to achieve a particular output profile. An encapsulant 404 is disposed over the chips 402 so that most of the light emitted passes through the encapsulant 404 into the ambient space. The encapsulant 404 comprises a textured surface 406 that randomizes the emission angle of light rays emitted from the various chips 402, improving the color temperature uniformity of the device 400. The textured surface 406 also reduces TIR. As shown, many chips can be mounted and covered with single encapsulant layer. This particular embodiment features 24 chips. More or fewer chips may be used according to design needs. The encapsulant can be formed or deposited on the mount surface and the chips 402 using a mold, for example.
FIG. 5 shows a top plan view of a mold device 500 used to shape several encapsulants simultaneously for inclusion in a chip-scale package LED. The mold device 500 comprises several cavities 502 arranged in an array on a mold base 504. The width of the cavities may be only slightly larger than the width of a single chip, or the cavities 504 may be wider to accommodate multi-chip arrays and other elements that will be covered by the encapsulant. A plurality of bore holes 506 can be used to mount the mold base 504 to a surface to steady the device during processing. Several LED devices (not shown) can be positioned so that each device is located within or adjacent to the space created by each cavity 502. For example, if the mold device is positioned over the LED devices, each of the devices should be located beneath one of the cavities 502. An encapsulant material can be injected into each of the cavities 502 prior to placing the mold device 500 over the LEDs for processing, or alternatively, the encapsulant material can be injected after the devices are in position as through fill hole (not shown). The encapsulant material may be cured at high temperatures using thermoset plastics, such as epoxies, silicones or hybrids of both.
Each of the cavities 502 has at least one irregular surface. Referring to FIG. 6, cavity 502 has an irregular bottom surface 508. The irregular bottom surface 508 has contours that shape the encapsulant material as it is hardened around the LED devices. When the encapsulant has been cured, the devices can be removed. The resulting encapsulant will have a textured top surface. The mold device 500 allows for encapsulants to be placed onto several LEDs and cured simultaneously. Each encapsulant formed using the mold will have a textured top surface. The inner surfaces of the cavities 502 can be roughened according to particular specifications to achieve a particular textured surface on the resulting molded encapsulants. The surface may have average peak-to-valley distances ranging from a few micrometers to several hundred micrometers, with an acceptable range being 1-200 micrometers.
FIG. 7 shows a cavity 700 that comprises multiple irregular surfaces 702. Multiple LED chips 704 can be enveloped under a common encapsulant as shown. The LED chips 704 are shown disposed adjacent to the cavity 700. The encapsulant material 706 is injected into the cavity 700 and cured. The resulting encapsulant has three textured surfaces that mirror the irregular surfaces 702 of the cavity 700. In some embodiments, the various surfaces may have different finishes. As discussed above the roughened encapsulant helps to improve light extraction and color temperature uniformity of the packaged LED devices.
FIG. 8 is a cross-sectional view of an embodiment of an LED package device 800. An LED chip 802 is disposed on a mount surface 804 which can be part of a package. First and second electrodes 806, 808 are arranged to provide a bias to the LED chip 802. In this particular embodiment, both of the electrodes 806, 808 are accessible from the side of the device 800 which is opposite from the primary emission surface. Vias 810 provide a path for current to travel from the bottom side of the mount surface 804 up to the LED chip 802. The second electrode 808 can be connected to the LED chip 802 with a wire bond (not shown).
An encapsulant 812 is disposed over the LED chip 802, the mount surface 804, and the electrodes 806, 808. The encapsulant 812 is flat, providing a primary emission surface 814 that is parallel to the mount surface 804. Some light may escape from encapsulant surfaces other than the primary emission surface 814 such as the side surfaces. In other embodiments these surfaces can also be modified by roughening. A mold similar to the one shown in FIG. 6 may be used to deposit the encapsulant 812 onto a chip package. Using a mold allows for many LED device packages to be encapsulated simultaneously. The devices can then be singulated by dicing or by other separation techniques known in the art. In other embodiments, an encapsulant having an emission surface that is conformal with all of the chip package components may be deposited over the device.
Light is emitted from the LED chip 802 and interacts with the encapsulant 812. The primary emission surface 814 can be modified to improve light extraction and color temperature uniformity as discussed in detail above. If manufactured using a mold, for example, the surface 814 may comprise roughening features corresponding to the internal surfaces of the mold. The mount surface 804 and electrodes 806, 808 may comprise a reflective material (e.g., diffuse, specular, or a combination of both) so that light that is internally reflected is redirected back towards surface 814 for a second pass at emission. The LED package device 800 represents one of many packages that may be manufactured to include a flat encapsulant.
first and second electrodes, said first electrode comprising a first top surface, said first and second electrodes are accessible for electrical connection from a side of the LED device opposite said primary emission surface;
a substrate comprising one or more vias, wherein said one or more vias provide a path for current to travel from said side of the LED device opposite said primary emission surface;
a plurality of LED chips entirely on said first top surface; and
an encapsulant disposed proximate to said mount surface, said encapsulant comprising a textured primary emission surface and at least one side emission surface;
wherein all of said first top surface is covered by said encapsulant and wherein said plurality of LED chips and said encapsulant are configured such that light can be emitted from said LED device from said at least one side emission surface;
wherein all of a top surface of said substrate adjacent to said encapsulant is covered by at least a portion of said encapsulant such that said encapsulant extends to the edges of said top surface of said substrate.
2. The LED device of claim 1, wherein said plurality of LED chips comprises LED chips emitting at least two different spectra of light.
3. The LED device of claim 2, said plurality of LED chips comprising LED chips emitting a red spectrum, LED chips emitting a green spectrum, and LED chips emitting a blue spectrum.
4. The LED device of claim 2, said plurality of LED chips comprising LED chips emitting a red spectrum and LED chips emitting a white spectrum.
5. The LED device of claim 2, said plurality of LED chips comprising LED chips emitting a blue spectrum and LED chips emitting a yellow spectrum.
6. The LED device of claim 2, wherein said plurality of LED chips is arranged in a substantially linear array.
7. The LED device of claim 1, wherein said first top surface comprises a reflective material.
8. The LED device of claim 7, wherein said reflective material forms a specular reflector.
9. The LED device of claim 7, wherein said reflective material forms a diffuse reflector.
10. The LED device of claim 7, wherein said reflective material forms a combination of specular and diffuse reflectors.
11. The LED device of claim 7, wherein said reflective material has light scattering properties.
12. The LED device of claim 1, wherein said textured primary emission surface comprises additive features.
13. The LED device of claim 1, wherein said textured primary emission surface comprises subtractive features.
14. The LED device of claim 1, wherein said encapsulant forms an interface with an ambient medium such that that index of refraction differential at said interface is at least 0.4.
15. The LED device of claim 1, wherein said textured primary emission surface has an average peak-to-valley roughness of 1-50 micrometers.
16. The LED device of claim 15, wherein said textured primary emission surface has an average peak-to-valley roughness ranging from 50-200 micrometers.
17. The LED device of claim 1, wherein said encapsulant comprises a wavelength conversion material.
18. The LED device of claim 1, wherein said encapsulant comprises phosphors.
19. The LED device of claim 1, wherein said encapsulant adheres directly to said LED chips and said first top surface.
20. The LED device of claim 1, wherein said encapsulant is attached to said LED chips with an adhesive epoxy.
21. The LED device of claim 1, wherein said textured emission surface has a patterned texture.
22. The LED device of claim 1, wherein said textured emission surface has a random texture.
23. The LED device of claim 1, said at least one side emission surface comprising a textured surface.
24. The LED device of claim 23, wherein said primary emission surface and said at least one side emission surface have different textures.
25. The LED device of claim 1, wherein said encapsulant has a thickness ranging from 70-200 micrometers.
26. The LED device of claim 1, wherein said first top surface is reflective.
27. The LED device of claim 1, wherein said second electrode comprises a second top surface; and
wherein all of said second top surface is covered by said encapsulant.
28. The LED device of claim 27, wherein said first and second top surfaces are reflective.
US12/002,429 2007-12-14 2007-12-14 Textured encapsulant surface in LED packages Active US9431589B2 (en)
US12/002,429 US9431589B2 (en) 2007-12-14 2007-12-14 Textured encapsulant surface in LED packages
EP08170514.7A EP2071642B1 (en) 2007-12-14 2008-12-02 Textured encapsulant surface in led packages
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JP2012232743A JP2013016868A (en) 2007-12-14 2012-10-22 Textured encapsulant surface in led packages
JP2012232744A JP2013042166A (en) 2007-12-14 2012-10-22 Textured encapsulant surface in led packages
US20090152573A1 US20090152573A1 (en) 2009-06-18
US9431589B2 true US9431589B2 (en) 2016-08-30
ID=40404260
US12/002,429 Active US9431589B2 (en) 2007-12-14 2007-12-14 Textured encapsulant surface in LED packages
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