Source: http://www.google.es/patents/US8866166
Timestamp: 2017-10-20 00:01:52
Document Index: 29710700

Matched Legal Cases: ['Application No. 201080030486', 'Application No. 2010800304863', 'Application No. 2012', 'Application No. 2013', 'Application No. 30', 'Application No. 10', 'Application No. 29', 'Application No. 100305347', 'Application No. 100126672', 'Application No. 101102722']

Patente US8866166 - Solid state lighting device - Google Patentes
A light emission package includes at least one solid state emitter, a leadframe, and a body structure encasing a portion of the leadframe. At least one aperture is defined in an electrical lead to define multiple electrical lead segments, with at least a portion of the aperture disposed outside an exterior...http://www.google.es/patents/US8866166?utm_source=gb-gplus-sharePatente US8866166 - Solid state lighting device
Número de publicación US8866166 B2
Número de solicitud US 13/953,438
También publicado como CN102460751A, CN102460751B, EP2438631A2, EP2438631A4, US7923739, US8497522, US20100133554, US20110180827, US20140027801, WO2010141215A2, WO2010141215A3
Número de publicación 13953438, 953438, US 8866166 B2, US 8866166B2, US-B2-8866166, US8866166 B2, US8866166B2
Inventores Christopher P. Hussell
Citas de patentes (175), Otras citas (100), Citada por (1), Clasificaciones (14), Eventos legales (1)
US 8866166 B2
a heatsink element in thermal communication with the at least one solid state emitter;
a leadframe defining a plurality of electrical leads in electrical communication with the at least one solid state emitter; and
a body structure encasing at least a portion of the leadframe and arranged to retain the heatsink element, wherein the body structure defines a cavity, and the at least one solid state emitter is disposed within the cavity;
wherein the cavity is bounded by a floor, side wall portions, end wall portions, and transition wall portions;
wherein a transition wall portion is disposed between each respective side wall portion and end wall portion; and
wherein each side wall portion and each end wall portion includes a substantially straight upper edge, and each transition wall portion includes a curved or segmented upper edge transitioning from the upper edge of a side wall portion to the upper edge of an end wall portion.
2. The light emission package of claim 1, wherein each transition wall portion is inclined at a larger average angle, relative to a plane perpendicular to the floor, than each side wall portion and each end wall portion.
3. The light emission package of claim 1, wherein each side wall portion and each end wall portion is inclined at an angle of at least about 40 degrees relative to a plane perpendicular to the floor.
4. The light emission package of claim 1, wherein each transition wall portion comprises at least a section thereof that is inclined at an angle of at least about 50 degrees relative to a plane perpendicular to the floor.
5. The light emission package of claim 1, wherein the body structure has a length and a width that are substantially equal.
6. The light emission package of claim 1, wherein the at least one solid state emitter comprises a plurality of solid state emitters.
This application is a divisional of and claims priority to U.S. patent application Ser. No. 13/082,699 filed Apr. 8, 2011, which is a divisional of and claims priority to the filing date of U.S. patent application Ser. No. 12/479,318 filed Jun. 5, 2009, now U.S. Pat. No. 7,923,739, the disclosures of which are incorporated herein by reference in their entireties.
A solid state lighting device may include, for example, an organic or inorganic light emitting diode (“LED”) or a laser. Examples of packages as referenced above are disclosed in U.S. Patent Application Publication Nos. 2005/0269587, 2004/0126913, and 2004/0079957, which are commonly assigned to the same assignee of the present invention.
It is known to mount solid state light sources, such as semiconductor light emitting devices, in packages that may provide protection, color enhancement, focusing, and other utilities for light emitted by such sources. One example of a light emitting die package including at least one light emitting device, a molded body, a lead frame including multiple leads, a heatsink, and a lens is disclosed in U.S. Pat. No. 7,456,499, which is commonly assigned to the same assignee of the present invention. The molded body is formed around portions of the leadframe and defines an opening on the top side of the device, with the opening surrounding a mounting pad for at least one LED device.
The present invention relates to solid state light emitters, including packages for solid state light emitters and devices incorporating same, and methods for forming solid state light emitter devices.
In one aspect, the invention relates to a light emission package adapted for use with at least one solid state emitter, the package comprising: (A) a leadframe defining at least one electrical lead; and (B) a body structure encasing at least a portion of the leadframe, the body structure defining at least one exterior side wall; wherein a first electrical lead of the at least one electrical lead includes a plurality of first electrical lead segments extending through the at least one exterior side wall, wherein each first electrical lead segment is separated from each other first electrical lead segment along the at least one exterior side wall by at least one first aperture, and at least a portion of the at least one first aperture is disposed outside the at least one exterior wall.
In another aspect, the invention relates to a light emission package adapted for use with at least one solid state emitter, the package comprising: (A) a leadframe defining at least one electrical lead; and (B) a body structure encasing at least a portion of the leadframe, the body structure defining at least one exterior side wall; wherein the at least one electrical lead extends through the at least one exterior side wall; and wherein the at least one exterior side wall defines at least one recess arranged to receive a bent portion of the at least one electrical lead.
In a further aspect, the invention relates to a method for fabricating a light emission package adapted for use with at least one solid state emitter, the method comprising: (A) forming a body structure to (i) encase at least a portion of a leadframe defining at least one electrical lead, and (ii) form at least one exterior side wall defining at least one recess; and (B) bending the at least one electrical lead to position at least a portion of the at least one electrical lead within the at least one recess. Such bending may be performed after forming of the body structure.
A further aspect of the invention relates to a method for fabricating a light emission package adapted for use with at least one solid state emitter, the method comprising: (A) defining in a leadframe at least one first aperture to yield a plurality of first electrical lead segments associated with a first electrical lead; (B) forming a body structure to (i) encase at least a portion of the leadframe and (ii) form at least one exterior side wall, wherein upon said forming of the body structure, each first electrical lead segment is separated from each other first electrical lead segment along the at least one exterior side wall by the at least one first aperture, and at least a portion of the at least one first aperture is disposed outside the at least one exterior wall; and (C) bending the plurality of first electrical lead segments. Such bending may be performed after forming of the body structure.
A still further aspect of the invention relates to a light emission package comprising: (A) at least one solid state emitter; (B) a heatsink element in thermal communication with the at least one solid state emitter; (C) a leadframe defining a plurality of electrical leads in electrical communication with the at least one solid state emitter; and (D) a body structure encasing at least a portion of the leadframe and arranged to retain the heatsink element, wherein the body structure defines a cavity, and the at least one solid state emitter is disposed within the cavity; wherein the cavity is bounded by a floor, side wall portions, end wall portions, and transition wall portions; wherein a transition wall portion is disposed between each respective side wall portion and end wall portion; and wherein each side wall portion and each end wall portion includes a substantially straight upper edge, and each transition wall portion includes a curved or segmented upper edge transitioning from the upper edge of a side wall portion to the upper edge of an end wall portion.
It will be understood that although the terms “first” and “second” are used herein to describe various regions, layers and/or portions, these regions, layers and/or portions should not be limited by these terms. These terms are only used to distinguish one region, layer or portion from another region, layer or portion. Thus, a first region, layer or portion discussed below could be termed a second region, layer or portion, and similarly, a second region, layer or portion may be termed a first region, layer or portion without departing from the teachings of the present invention.
Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe relationship of one or more elements to another elements as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if a device in the Figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower,” can therefore, encompasses both an orientation of “lower” and “upper,” depending of the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The terms “below” or “beneath” can therefore encompass both an orientation of above and below.
Solid state light emitting devices according to embodiments of the invention may include III-V nitride (e.g., gallium nitride) based LEDs or lasers fabricated on a silicon carbide substrate, such as those devices manufactured and sold by Cree, Inc. of Durham, N.C. Such LEDs and/or lasers may be configured to operate such that light emission occurs through the substrate in a so-called “flip chip” orientation.
Referring now to FIGS. 1-6, a solid state light emitter package 100 according to certain embodiments of the present invention includes a body structure 10 defining a body cavity (preferably reflective to constitute a reflector cavity) 20 containing six solid state emitters 12A-12F. Each emitter 12A-12F is arranged over (i.e., on or adjacent to) the upper surface 71 of a heatsink 70 disposed along the floor of the reflector cavity 20, and each emitter 12A-12F is disposed in electrical communication with a first electrical lead 51 and a second electrical lead 61 using wirebonds 31, 32. In one embodiment, the emitters 12A-12F may be mounted on an optional submount (not shown) arranged between the emitters 12A-12F and the heatsink 70. The heatsink 70 is separated from (and preferably electrically isolated from) the electrical leads 51, 52 via body portions 19A, 19B, and is adapted to conduct heat away from the emitters 12A-12F to a lower surface 72 of the heatsink 70 for dissipation therefrom. An electrostatic discharge protection device 9 (e.g., a zener diode, or alternatively, a ceramic capacitor, transient voltage suppression (TVS) diode, multilayer varistor, and/or Schottky diode) arranged on the first electrical lead 51 and having an associated wirebond 33 is also disposed in electrical communication with the emitters 12A-12F. The electrical leads 51, 61 extend through exterior side walls 15, 16 disposed at opposing ends of the body structure 10, with lead tab portions 56, 66 extending away from the exterior side walls 15, 16 in a direction outward from a center portion of the package 100, to enable the lead tab portions 56, 66 to be soldered or otherwise connected to a current source and sink (not shown) to permit operation of the emitters 12A-12F.
The body structure 10 includes an upper face 11, lower face 13, and exterior side walls 15-18. The upper face 11 defines a corner notch 1, and the lower face 13 desirably includes a recess 2 containing the heatsink 70, with a lower surface 72 and lower protrusion 72A of the heatsink 70 being exposed. In one embodiment, the body structure 10 has a length and a width (e.g., as represented by exterior side walls 15-18) that are substantially equal, such that the body structure 10 has a square-shaped footprint. In another embodiments, the length and width of the body structure 10 may be unequal, with the body structure having a rectangular footprint, or the body structure 10 may be formed in other shapes (e.g., round), including footprints conforming to regular polygonal shapes (e.g., octagonal), or footprints of other shapes not constituting regular polygons. The body structure 10 is preferably formed around a leadframe 50 (defining electrical leads 51, 61) and the heatsink 70 (as illustrated in FIG. 6), with the body structure 10 encasing at least a portion of the leadframe 50 and arranged to retain the heatsink element 70. Protruding portions 73, 74 of the heatsink 70 may be exposed along side walls 17, 18 of the body structure 10. The body structure 10 may be advantageously formed using a molding process, such as injection molding, using a thermoplastic and/or thermoset material that is preferably electrically insulating. Polymer-containing materials are desirably used to form the body structure 10, with such materials optionally being reinforced (e.g., with fibers, ceramics, or composites). The body structure may be white or light in color to minimize dark appearance of the package 100. Ceramic and/or composite materials may be utilized in place of polymers to form the body structure 10 in certain embodiments. As an alternative to injection molding, other types of molding and/or forming processes (e.g., sintering) may be used. The body structure 10 may include an upper portion 10A and lower portion 10B (e.g., as may be formed in upper and lower molding die portions (not shown), respectively). The reflector cavity 20 may be formed as the inverse of a central protrusion in an upper molding die.
Referring to FIG. 3 and FIG. 7, the reflector cavity 20 is bounded from below by a floor (including portions of the contacts 51, 61, body portions 19A, 19B, and an upper surface 71 of the heatsink 70), and bounded along edges by side wall portions 21A, 21B, end wall portions 22A, 22B, and transition wall portions 24A-24D. A transition wall portion 24A-24D is disposed between each respective side wall portion 21A, 21B and end wall portion 22A, 22B. Each side wall portion 21A, 21B and each end wall portion 22A, 22B preferably includes a substantially straight upper edge, and each transition wall portion 24A-24D preferably includes a curved or segmented upper edge transitioning from the upper edge of a side wall portion 21A, 21B to the upper edge of an end wall portion 22A, 22B. Each transition wall portion 24A-24D is preferably inclined at a larger average angle, relative to a plane perpendicular to the floor of the reflector cavity, than each side wall portion 21A, 21B and each end wall portion 22A, 22B. For example, FIG. 8A provides a simplified schematic cross-sectional view of a body portion, illustrating the angle θ of a side wall portion or end wall portion thereof relative to a plane perpendicular to the floor of the body cavity. Similarly, FIG. 8B provides a simplified schematic cross-sectional view of a body portion, illustrating the angle φ of a transition wall portion relative to a plane perpendicular to the floor of the body cavity. In one embodiment, each side wall portion and each end wall portion is inclined at an angle θ of at least about 20 degrees; more preferably at least about 30 degrees; still more preferably at least about 40 degrees. In further embodiments, the angle θ may be at least about 45 degrees, or at least about 50 degrees. In one each transition wall portion is inclined at an angle φ of at least about 30 degrees; more preferably at least about 40 degrees; still more preferably at least about 50 degrees. In further embodiments, the angle φ may be at least about 55 degrees, or at least about 60 degrees. Such angles of the side wall portions 21A, 21B, end wall portions 22A, 22B, and transition wall portions 24A, 24D are greater than typically employed in solid state emitter devices. Although the side wall/end wall portions and transition wall portions are illustrated in FIGS. 8A-8B as being angular from the floor of the cavity to the upper edge of the package, in an alternative embodiment any one or more (or all) of these wall portions may be characterized by a segmented and/or curved cross-section, that is, with the wall extending from the floor to the upper edge of the package being non-linear along at least a portion thereof. If such walls are curved or segmented, then the inclination angles mentioned above may correspond to an average angle of a curved or segmented wall, or an angle between endpoints of such a wall. Use of side wall portions 21A, 21B/end wall portions 22A, 22B and transition wall portions 24A-24D of alternating angles enables frontal area of the reflector cavity 20 maximized relative to the square-shaped upper surface 11, while providing desirably diffuse output beam characteristics, particularly when multiple emitters are disposed in the cavity 20.
As indicated previously, the body structure 10 is preferably formed around the leadframe 50 and heatsink 70. Referring to FIGS. 10-11, the leadframe 50 includes a first electrical lead 51 and a second electrical lead 61. Each electrical lead 51, 61 includes a medial end 58, 68, and a lead tab portion 56, 66 extending away from a center of the emitter package and terminating at a distal end 59, 69. Each electrical lead 51, 61 defines at least one aperture 52, 62 that serves to separate multiple electrical lead segments 51A-51B, 61A-62B. In one embodiment, each electrical lead 51, 61 may include multiple apertures serving to separate more than two (e.g., three or more) electrical lead segments. A portion of each aperture 52, 62 is preferably filled with body material of the body structure, with another portion of each aperture 52, 62 being disposed outside the side walls 15, 16 of the body structure 10, such that individual electrical lead segments 51A-51B, 61A-61B are separated from corresponding electrical lead segments 51A-51B, 61A-61B by the apertures 52, 62 along exterior side walls 15, 16 of the body structure 10. Each electrical lead 51, 61 includes a first bend 53, 63, a bent portion 54, 64 (that is preferably substantially perpendicular to a plane extending through the medial ends 58, 68), and a second bend 55, 65 transitioning to each electrical lead tab portion 56, 66. Each aperture 52, 62 preferably extends at least into each first bend 53, 63. Each aperture 52, 62 provides multiple benefits. First, a medial portion of each aperture 52, 62 is filled with body material, and thus serves to promote secure retention of the electrical leads 51, 61 within the body structure 10. Second, each aperture 52, 62 serves to reduce the amount of lead material (e.g., metal) subject to being bent to form the first bend 53, 63. This reduces the amount of bending force required to form the first bend 53, 63, as is particularly desirable when the first bend 53, 63 is formed in each electrical lead 51, 61 after formation of the body structure 10 around the electrical leads 51, 61. Bending is preferably performed sufficiently to position at least a portion of each electrical lead 51, 61 in the recesses 5, 6.
FIG. 13 shows a top plan view photograph of a solid state emitter package 300 similar to the package 100 described hereinabove. To promote ease of viewing, such package 300 is devoid of encapsulant, diffuser, and/or lens material (as otherwise may be retained in the cavity to cover/protect the emitters and wirebonds, and to optionally interact with light emitted by the emitters), but it is to be understood that emitter packages as disclosed herein may desirably include encapsulant, diffuser and/or lens material, optionally including at least one lumiphor to interact with light emitted by the emitters and responsively emit light of a different wavelength. The package 300 according to the present embodiment differs from the package 100 according to a prior embodiment with respect to layout of the wirebonds (e.g., the wirebond of the electrostatic discharge device may extend to a second contact, rather than contacting a wirebond for an emitter), and with respect to size of the apertures defined in the electrical leads. As compared to the apertures 52, 62 defined in the electrical leads 51, 61, the apertures shown in FIG. 13 are larger.
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77 Notice of Allowance for U.S. Appl. No. 29/397,017 dated Dec. 9, 2011.
78 Notice of Allowance for U.S. Appl. No. 29/397,017 dated May 17, 2012.
79 Notice of Allowance for U.S. Appl. No. 29/401,692 dated Jan. 20, 2012.
80 Notice of Allowance for U.S. Appl. No. 29/432,988 dated Sep. 10, 2013.
81 Notice of Allowance for U.S. Appl. No. 29/451,761 dated Dec. 11, 2013.
82 Notice of Allowance from U.S. Appl. No. 29/330,657 dated Sep. 25, 2009.
83 Notification Concerning Availability of the Publication Serial No. PCT/US2012/023285 dated Aug. 9, 2012.
84 Notification Concerning Availability of the Publication Serial No. PCT/US2012/024122 dated Aug. 16, 2012.
85 Notification of Grant for Chinese Application Serial No. CN 2010-305787293.2 dated Jan. 19, 2012.
86 Notification of Grant for Chinese Application Serial No. CN 2011/30210595.0 dated Jan. 17, 2012.
87 Office Action with Restriction/Election Requirement for U.S. Appl. No. 12/853,812 dated Sep. 22, 2011.
88 Restriction Requirement for Application No. 29/382,394 dated Jul. 17, 2012.
89 Restriction Requirement for U.S. Appl. No. 29/451,761 dated Sep. 25, 2013.
90 Supplemental Notice of Allowability for U.S. Appl. No. 12/479,318 dated Apr. 5, 2011.
91 Supplemental Notice of Allowance for Design U.S. Appl. No. 29/338,186 dated May 20, 2011.
92 Supplemental Notice of Allowance for U.S. Appl. No. 29/353,652 dated Dec. 8, 2010.
93 Supplemental Notice of Allowance for U.S. Appl. No. 29/360,791 dated Jan. 24, 2011.
94 Supplemental Notice of Allowance for U.S. Appl. No. 29/382,394 dated Jan. 14, 2013.
95 Supplemental Notice of Allowance for U.S. Appl. No. 29/397,017 dated Jul. 23, 2012.
96 Taiwanese Notice of Allowance for Application No. 100305347 dated Mar. 23, 2012.
97 Taiwanese Office Action and Search Report for Application No. 100126672 dated Dec. 26, 2013.
98 Taiwanese Office Action for Appl. No. 099305566 dated Jul. 12, 2011.
99 Taiwanese Office Action for Application No. 101102722 dated Jan. 28, 2014.
100 U.S. Appl. No. 12/969,267 filed Dec. 15, 2010.
Clasificación de EE.UU. 257/91, 257/172, 257/99
Clasificación internacional H01L33/48, H01L25/075, H01L33/62
Clasificación cooperativa H01L33/642, Y10T29/49002, H01L2924/12032, H01L2224/48465, H01L33/486, H01L2224/49113, H01L25/0753, H01L33/62
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