Patent ID: 8841145

Claim:
A method for phosphor deposition on a semiconductor wafer, the method comprising: depositing a semiconductor wafer having a plurality of light emitting diode (“LED”) dies on a carrier wafer; covering a first surface of the semiconductor wafer with a photo resist material layer having a first height; removing at least a portion of the photo resist material layer to expose at least a portion of the semiconductor wafer and preserving remaining photo resist material layer to form a plurality of posts having the first height covering electrical contacts associated with the plurality of LED dies from exposure, wherein preserving remaining photo resist material layer to form a plurality of posts includes substantially aligning bottom surfaces of the plurality of posts in a first plain, wherein no post has a bottom surface in a plain different than the first plain; depositing a phosphor layer with a substantial uniform thickness having a second height only on the exposed portions of the semiconductor wafer and allowing the second height of phosphor layer to be lower than the first height of the plurality of posts, and allowing a portion of the phosphor layer to contact at least part of circumference of one of the plurality of posts, wherein depositing the phosphor layer includes allowing bottom surface of the phosphor layer to be substantially aligned; and removing the remaining photo resist material after depositing the phosphor to expose the electrical contacts.