Converter with glass layers

Patent metadata

Field	Value
Publication number	US-11973168-B2
Application number	US-202318122520-A
Country	US
Kind code	B2
Filing date	Mar 16, 2023
Priority date	Dec 20, 2017
Publication date	Apr 30, 2024
Grant date	Apr 30, 2024

Abstract

A wavelength converting layer may have a glass or a silicon porous support structure. The wavelength converting layer may also have a cured portion of wavelength converting particles and a binder laminated onto the porous glass or silicon support structure.

First claim

What is claimed is:

1. A wavelength converting layer comprising:
a porous support structure including one or more quartz or glass mesh layers; and
a cured layer of wavelength converting particles and a binder laminated onto the porous support structure,
all or at least a portion of the thickness of the porous support structure lacking any of the wavelength converting particles, and
all or at least a portion of the thickness of the cured layer lacking any fibers or strings of the one or more mesh layers.

2. The wavelength converting layer of claim 1 , wherein the binder includes a silicone.

3. The wavelength converting layer of claim 1 , wherein the one or more mesh layers include woven support material.

4. The wavelength converting layer of claim 3 , wherein a first woven support material includes the fibers or strings, and the fibers or strings extend across substantially 100% of a transverse dimension of the one or more mesh layers.

5. The wavelength converting layer of claim 1 , wherein the binder includes one or more fillers configured to increase a refractive index.

6. The wavelength converting layer of claim 1 , wherein the wavelength converting particles include phosphor particles or pre-formed ceramic phosphor.

7. A light emitting device comprising:
a wavelength converting layer, and
a semiconductor active layer,
the wavelength converting layer including a porous support structure including one or more quartz or glass mesh layers, and a cured layer of wavelength converting particles and a binder laminated onto the porous support structure,
all or at least a portion of the thickness of the porous support structure lacking any of the wavelength converting particles,
all or at least a portion of the thickness of the cured layer lacking any fibers or strings of the one or more mesh layers, and
the wavelength converting layer being positioned and arranged to absorb first light emitted from the active layer at a first wavelength, and to emit second light at a second wavelength different from the first wavelength.

8. The light emitting device of claim 7 , wherein the binder includes a silicone.

9. The light emitting device of claim 7 , wherein the one or more mesh layers include woven support material.

10. The light emitting device of claim 9 , wherein a first woven support material includes the fibers or strings, and the fibers or strings extend across substantially 100% of a transverse dimension of the one or more mesh layers.

11. The light emitting device of claim 7 , wherein the binder includes one or more fillers configured to increase a refractive index.

12. The light emitting device of claim 7 , wherein the wavelength converting particles include phosphor particles or pre-formed ceramic phosphor.

13. A method comprising:
forming a porous support structure that includes one or more quartz or glass mesh layers;
forming a layer that includes wavelength converting particles and a binder; and
heat or pressure laminating the layer of the wavelength converting particles and the binder onto the porous support structure to form a laminated wavelength converting layer, so that all or at least a portion of the thickness of the porous support structure lacks any of the wavelength converting particles, and so that all or at least a portion of the thickness of the layer of the wavelength converting particles and the binder lacks any fibers or strings of the one or more mesh layers.

14. The method of claim 13 wherein the wavelength converting particles and the binder are characterized by a first color point, the method further comprising:
forming a layer that includes second wavelength converting particles and a second binder, wherein the second wavelength converting particles and the second binder are characterized by a second color point that differs from the first color point; and
heat or pressure laminating the layer of the second wavelength converting particles and the second binder onto the porous support structure of the wavelength converting layer, so that (i) the wavelength converting layer exhibits a predetermined color point, (ii) all or at least a portion of the thickness of the porous support structure lacks any of the second wavelength converting particles, and (iii) all or at least a portion of the thickness of the layer of the second wavelength converting particles and the second binder lacks any fibers or strings of the one or more mesh layers.

15. The method of claim 13 further comprising attaching multiple semiconductor light emitting devices to corresponding portions of the layer of the wavelength converting particles and the binder of the laminated wavelength converting layer, each portion of the laminated wavelength converting layer being positioned and arranged to absorb first light emitted by an active layer of the corresponding attached light emitting device at a first wavelength, and to emit second light at a second wavelength different from the first wavelength.

16. The method of claim 15 further comprising:
before attaching the light emitting devices, singulating the laminated wavelength converting layer, and
positioning each light emitting device against a corresponding singulated portion of the laminated wavelength converting layer.

17. The method of claim 15 further comprising, after attaching the light emitting devices, singulating the laminated wavelength converting layer so that each light emitting device is attached to a corresponding singulated portion of the laminated wavelength converting layer.

18. The method of claim 13 wherein the binder includes a silicone, or the wavelength converting particles include phosphor particles or pre-formed ceramic phosphor.

19. The method of claim 13 wherein the stacked one or more mesh layers include woven support material.

20. The method of claim 13 , wherein the binder includes one or more fillers to increase a refractive index.

Assignees

• Lumileds Llc

Inventors

• Basin Grigoriy
• Ng Mooi Guan
• Kosowsky Lex Alan
• Barton Phillip

Classifications

• H10H20/0362

  of encapsulations · CPC title

• H10H20/856

  Reflecting means · CPC title

• H10H20/0361

  of wavelength conversion means · CPC title

• H10H20/854

  characterised by their material, e.g. epoxy or silicone resins · CPC title

• H10H20/8514

  characterised by their shape, e.g. plate or foil · CPC title