U.S. patent application number 14/041193 was filed with the patent office on 2014-03-06 for light-emitting dies incorporating wavelength-conversion materials and related methods.
The applicant listed for this patent is Michael A. Tischler. Invention is credited to Michael A. Tischler.
Application Number | 20140061705 14/041193 |
Document ID | / |
Family ID | 47679036 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140061705 |
Kind Code |
A1 |
Tischler; Michael A. |
March 6, 2014 |
LIGHT-EMITTING DIES INCORPORATING WAVELENGTH-CONVERSION MATERIALS
AND RELATED METHODS
Abstract
In accordance with certain embodiments, semiconductor dies are
embedded within polymeric binder to form, e.g., freestanding white
light-emitting dies and/or composite wafers containing multiple
light-emitting dies embedded in a single volume of binder.
Inventors: |
Tischler; Michael A.;
(Vancouver, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tischler; Michael A. |
Vancouver |
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CA |
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|
Family ID: |
47679036 |
Appl. No.: |
14/041193 |
Filed: |
September 30, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13768267 |
Feb 15, 2013 |
8629475 |
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14041193 |
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13748864 |
Jan 24, 2013 |
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13768267 |
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61589908 |
Jan 24, 2012 |
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61589909 |
Jan 24, 2012 |
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Current U.S.
Class: |
257/98 |
Current CPC
Class: |
H01L 33/486 20130101;
H05B 33/12 20130101; H01L 33/501 20130101; H01L 24/96 20130101;
H01L 2924/07811 20130101; H01L 31/048 20130101; H01L 2924/1815
20130101; H01L 24/97 20130101; H05B 33/02 20130101; H01L 31/0203
20130101; H01L 2924/01005 20130101; H01L 33/60 20130101; H01L
31/055 20130101; H01L 2924/12041 20130101; H01L 2933/0033 20130101;
H01L 31/022425 20130101; H01L 31/02327 20130101; H01L 2924/12043
20130101; H01L 25/00 20130101; H01L 2924/07802 20130101; H01L
2924/181 20130101; H01L 2224/73259 20130101; H01L 2224/16145
20130101; H01L 2924/12032 20130101; Y02E 10/52 20130101; H01L
2933/0041 20130101; H01L 31/02322 20130101; H01L 29/00 20130101;
H01L 33/505 20130101; H01L 2924/12042 20130101; H01L 21/00
20130101; H01L 25/0753 20130101; H01L 27/14 20130101; H01L
2924/07811 20130101; H01L 2924/00 20130101; H01L 2924/07802
20130101; H01L 2924/00 20130101; H01L 2924/12041 20130101; H01L
2924/00 20130101; H01L 2924/12032 20130101; H01L 2924/00 20130101;
H01L 2924/181 20130101; H01L 2924/00 20130101; H01L 2924/12042
20130101; H01L 2924/00 20130101; H01L 2924/12043 20130101; H01L
2924/00 20130101 |
Class at
Publication: |
257/98 |
International
Class: |
H01L 33/10 20060101
H01L033/10 |
Claims
1-30. (canceled)
31. A composite wafer comprising: a solid volume of a polymeric
binder having a first surface and a second surface opposite the
first surface; suspended within the polymeric binder, a plurality
of semiconductor dies each (i) having a first face, a second face
opposite the first face, and at least one sidewall spanning the
first and second faces, and (ii) being a bare-die light-emitting
element comprising a plurality of active semiconductor layers that
cooperatively emit light; a reflecting layer disposed on a surface
of the polymeric binder or disposed within at least a portion of
the polymeric binder proximate at least one semiconductor die; and
disposed on the first face of each semiconductor die, at least two
spaced-apart contacts each having a free terminal end (i) at least
a portion of which is not covered by the polymeric binder and (ii)
available for electrical connection, the contacts each contacting a
different active semiconductor layer of the semiconductor die,
wherein (i) at least a portion of the polymeric binder is
transparent to a wavelength of light emitted by at least one of the
semiconductor dies, (ii) the polymeric binder contains therein a
wavelength-conversion material for absorption of at least a portion
of light emitted from at least one of the semiconductor dies and
emission of converted light having a different wavelength,
converted light and unconverted light emitted by at least one
semiconductor die combining to form substantially white light
having a correlated color temperature in the range of 2000 K to
10,000 K, (iii) a variation in color temperature of the white light
emitted when each semiconductor die is individually energized is
less than 500 K, and (iv) the reflecting layer has a reflectivity
of at least 50% to a wavelength of light emitted by at least one
semiconductor die or to a wavelength of light emitted by the
wavelength-conversion material.
32. The composite wafer of claim 31, wherein at least portions of
the contacts of at least some of the semiconductor dies protrude
from the polymeric binder.
33. The composite wafer of claim 31, wherein at least portions of
the contacts of all of the semiconductor dies protrude from the
polymeric binder.
34. The composite wafer of claim 31, wherein at least a portion of
each said sidewall of at least some of the semiconductor dies
protrudes from the first surface of the polymeric binder.
35. The composite wafer of claim 31, wherein the polymeric binder
comprises at least one of silicone or epoxy.
36. The composite wafer of claim 31, wherein the
wavelength-conversion material comprises at least one of a phosphor
or quantum dots.
37. The composite wafer of claim 31, wherein each semiconductor die
comprises a bare-die light-emitting diode.
38. The composite wafer of claim 31, wherein each semiconductor die
comprises a semiconductor material comprising at least one of GaAs,
AlAs, InAs, GaP, AlP, InP, ZnO, CdSe, CdTe, ZnTe, GaN, AlN, InN,
silicon, or an alloy or mixture thereof.
39. The composite wafer of claim 31, wherein the substantially
white light has a variation in color temperature of less than four
MacAdam ellipses across the composite wafer.
40. The composite wafer of claim 31, wherein the substantially
white light has a variation in color temperature of less than two
MacAdam ellipses across the composite wafer.
41. The composite wafer of claim 31, wherein the polymeric binder
has a substantially uniform thickness with a thickness variation
less than 10%.
42. The composite wafer of claim 31, wherein a thickness of the
polymeric binder above each of the plurality of semiconductor dies
is the same to within 5%.
43. The composite wafer of claim 31, wherein the semiconductor dies
are arranged in an array having substantially equal distances
between semiconductor dies in at least a first direction.
44. The composite wafer of claim 43, wherein the array of
semiconductor dies has substantially equal distances between
semiconductor dies in a second direction different from the first
direction.
45. The composite wafer of claim 31, wherein at least a portion of
the surface of the polymeric binder is textured with a texture for
enhancing light extraction from the polymeric binder.
46. The composite wafer of claim 45, wherein the texture has an
average roughness in the range of about 0.5 .mu.m to about 10
.mu.m.
47. The composite wafer of claim 31, further comprising at least
one optical element positioned to receive light from at least one
of the semiconductor dies.
48. The composite wafer of claim 47, wherein the at least one
optical element comprises a plurality of optical elements each
associated with at least one semiconductor die.
49. The composite wafer of claim 31, wherein the reflecting layer
comprises at least one of (i) a reflecting film or (ii) a plurality
of particles.
50. The composite wafer of claim 31, wherein the polymeric binder
comprises a plurality of discrete regions, at least one of which
comprises the polymeric binder without the wavelength-conversion
material.
51. The composite wafer of claim 31, wherein the active
semiconductor layers of at least one semiconductor die are not
disposed on a semiconductor substrate.
52. The composite wafer of claim 31, wherein the polymeric binder
comprises a plurality of shaped regions, each shaped region (i)
associated with at least one semiconductor die and (ii) having a
shape substantially identical to shapes of the other shaped
regions.
53. The composite wafer of claim 31, wherein the reflectivity of
the reflecting layer to the wavelength of light emitted by at least
one semiconductor die or to the wavelength of light emitted by the
wavelength-conversion material is at least 75%.
54. The composite wafer of claim 31, wherein the variation in color
temperature of the white light emitted when each semiconductor die
is individually energized is less than 250 K.
55. The composite wafer of claim 31, wherein a thickness of the
polymeric binder above a first semiconductor die is different from
a thickness of the polymeric binder above a second semiconductor
die different from the first semiconductor die.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/768,267, filed Feb. 15, 2013, which is a
continuation of U.S. patent application Ser. No. 13/748,864, filed
Jan. 24, 2013, which claims the benefit of and priority to U.S.
Provisional Patent Application No. 61/589,908, filed Jan. 24, 2012,
and U.S. Provisional Patent Application No. 61/589,909, filed Jan.
24, 2012, the entire disclosure of each of which is hereby
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] In various embodiments, the present invention generally
relates to light sources, and more specifically to
phosphor-converted light sources.
BACKGROUND
[0003] Light sources such as light-emitting diodes (LEDs) are an
attractive alternative to incandescent and fluorescent light bulbs
in illumination devices due to their higher efficiency, smaller
form factor, longer lifetime, and enhanced mechanical robustness.
However, the high cost of LED-based lighting systems has limited
their widespread utilization, particularly in broad-area general
lighting applications.
[0004] The high cost of LED-based lighting systems has several
contributors. LEDs are typically encased in a package, and multiple
packaged LEDs are used in each lighting system to achieve the
desired light intensity. For general illumination, which utilizes
white light, such white light may be generated in a number of ways.
One approach is to utilize two or more LEDs operating at different
wavelengths, where the different wavelengths combine to appear
white to the human eye. For example, LEDs emitting in the red,
green and blue wavelength ranges may be utilized together. Such an
arrangement typically requires careful control of the operating
currents of each LED, such that the resulting combination of
wavelengths is stable over time and different operating conditions,
for example temperature. The different LEDs may also be formed of
different materials, for example, AlInGaP for red LEDs and AlInGaN
for blue and green LEDs. These different materials may have
different operating current requirements as well as different
temperature dependencies of the light output power and wavelength.
Furthermore, changes in light-output power with time may be
different for each type of LED. Therefore, such systems typically
utilize some form of active control of the current in each LED to
maintain the light output power of each LED at the desired level.
In some implementations one or more sensors (for example to sense
light intensity, light color, temperature or the like) may be used
to provide feedback to the current-control system, while in some
other implementations the current may be adjusted over time based
on values in a look-up table. Such control systems add cost and
complexity to lighting solutions, as well as creating additional
failure points. A further disadvantage of multi-LED arrangements is
that they typically require some form of light combiner, diffuser
or mixing chamber, so that the eye observes white light rather than
the discrete different colors of each of the different LEDs. Such
light-mixing systems typically add cost and bulk to lighting
systems as well as reducing their efficiency.
[0005] White light may also be produced in LED-based arrangements
for general illumination by means of light-conversion materials
such as phosphors. LEDs generally emit in a relatively narrow
wavelength range, for example on the order of about 20-100 nm. When
broader spectra (for example "white" light) or colors different
from that of the LED are desired, the LED may be combined with one
or more light-conversion materials. An LED combined with one or
more phosphors typically generates white light by combining the
short-wavelength emission from the semiconductor LED with
long-wavelength emission from the phosphor(s). This occurs because
a portion of the LED light passes unconverted through the phosphor
to combine with the phosphor-converted light. Phosphors are
typically composed of phosphorescent particles such as
Y.sub.3Al.sub.5O.sub.12:Ce.sup.3+ (cerium-activated
yttrium-aluminum-garnet, or YAG:Ce) embedded in a transparent
binder such as optical epoxy or silicone and applied as a layer.
However, phosphor integration is often difficult, particularly in
terms of uniformity and reproducibility of the resulting light.
[0006] In some phosphor implementations, the phosphor layer absorbs
a portion of the incident short-wavelength radiant flux and
re-emits long-wavelength radiant flux. In an exemplary YAG:Ce
phosphor, as depicted by the graph in FIG. 1, a blue LED typically
has a peak wavelength of 450 nm-460 nm, corresponding to the peak
of the phosphor-excitation spectrum, while the phosphor emission
has a broadband spectrum with a peak at approximately 560 nm.
Combining the blue LED emission with the yellow phosphor emission
yields visible white light with a specific chromaticity (color)
that depends on the ratio of blue to yellow light. Herein, "white
light" may be white or any other color that is produced by a
combination of light from one or more light emitters and one or
more light-conversion materials.
[0007] The geometry of the phosphor relative to the LED generally
has a very strong impact on the uniformity of the light
characteristics. For example, the LED may emit from more than one
surface, for example from the top and the sides of the LED,
producing non-uniform color if the phosphor composition is not
uniform over these LED surfaces. More complicated structures may be
used to attempt to mitigate this problem, but these add cost and
complexity and may be additional sources for reliability
problems.
[0008] Furthermore, if the thickness of the phosphor layer, formed
of a uniformly dispersed phosphor in a binder, is not uniform over
the surface of the LED, relatively larger amounts of blue light
will be present where the phosphor-infused binder layer is thinner
and relatively smaller amounts of blue light will be present where
the phosphor-infused binder is thicker. In view of the foregoing, a
need exists for structures, systems and procedures enabling the
uniform and low cost integration of phosphors with LEDs.
SUMMARY
[0009] In accordance with certain embodiments, semiconductor dies
such as light-emitting elements (LEEs) are coated with a polymeric
binder, which is subsequently cured to form a composite wafer of
the solid binder material and the dies suspended therein. The
composite wafer may be divided into free-standing "white dies" each
composed of the die and a portion of the cured binder that at least
partially surrounds the die. The binder may advantageously contain
a wavelength-conversion material such as a phosphor or a collection
of quantum dots. Various mold substrates and/or molds may be
utilized to secure the semiconductor dies and/or to prevent coating
of the contacts of the dies during the coating process.
[0010] As utilized herein, the term "light-emitting element" (LEE)
refers to any device that emits electromagnetic radiation within a
wavelength regime of interest, for example, visible, infrared or
ultraviolet regime, when activated, by applying a potential
difference across the device or passing a current through the
device. Examples of LEEs include solid-state, organic, polymer,
phosphor-coated or high-flux LEDs, microLEDs (described below),
laser diodes or other similar devices as would be readily
understood. The emitted radiation of a LEE may be visible, such as
red, blue or green, or invisible, such as infrared or ultraviolet.
A LEE may produce radiation of a spread of wavelengths. A LEE may
feature a phosphorescent or fluorescent material for converting a
portion of its emissions from one set of wavelengths to another. A
LEE may include multiple LEEs, each emitting essentially the same
or different wavelengths. In some embodiments, a LEE is an LED that
may feature a reflector over all or a portion of its surface upon
which electrical contacts are positioned. The reflector may also be
formed over all or a portion of the contacts themselves. In some
embodiments, the contacts are themselves reflective.
[0011] A LEE may be of any size. In some embodiments, a LEEs has
one lateral dimension less than 500 .mu.m, while in other
embodiments a LEE has one lateral dimension greater than 500 um.
Exemplary sizes of a relatively small LEE may include about 175
.mu.m by about 250 .mu.m, about 250 .mu.m by about 400 .mu.m, about
250 .mu.m by about 300 .mu.m, or about 225 .mu.m by about 175
.mu.m. Exemplary sizes of a relatively large LEE may include about
1000 .mu.m by about 1000 .mu.m, about 500 .mu.m by about 500 .mu.m,
about 250 .mu.m by about 600 .mu.m, or about 1500 .mu.m by about
1500 .mu.m. In some embodiments, a LEE includes or consists
essentially of a small LED die, also referred to as a "microLED." A
microLED generally has one lateral dimension less than about 300
.mu.m. In some embodiments, the LEE has one lateral dimension less
than about 200 .mu.m or even less than about 100 .mu.m. For
example, a microLED may have a size of about 225 .mu.m by about 175
.mu.m or about 150 .mu.m by about 100 .mu.m or about 150 .mu.m by
about 50 .mu.m. In some embodiments, the surface area of the top
surface of a microLED is less than 50,000 .mu.m.sup.2 or less than
10,000 .mu.m.sup.2. The size of the LEE is not a limitation of the
present invention, and in other embodiments the LEE may be
relatively larger, e.g., the LEE may have one lateral dimension on
the order of at least about 1000 .mu.m or at least about 3000
.mu.m.
[0012] As used herein, "phosphor" refers to any material that
shifts the wavelengths of light irradiating it and/or that is
fluorescent and/or phosphorescent. As used herein, a "phosphor" may
refer to only the powder or particles (of one or more different
types) or to the powder or particles with the binder, and in some
circumstances may refer to region(s) containing only the binder
(for example, in a remote-phosphor configuration in which the
phosphor is spaced away from the LEE). The terms
"wavelength-conversion material" and "light-conversion material"
are utilized interchangeably with "phosphor" herein. The
light-conversion material is incorporated to shift one or more
wavelengths of at least a portion of the light emitted by LEEs to
other (i.e., different) desired wavelengths (which are then emitted
from the larger device alone or color-mixed with another portion of
the original light emitted by the LEE). A light-conversion material
may include or consist essentially of phosphor powders, quantum
dots or the like within a transparent binder. Phosphors are
typically available in the form of powders or particles, and in
such case may be mixed in binders. An exemplary binder is silicone,
i.e., polyorganosiloxane, which is most commonly
polydimethylsiloxane (PDMS). Phosphors vary in composition, and may
include lutetium aluminum garnet (LuAG or GAL), yttrium aluminum
garnet (YAG) or other phosphors known in the art. GAL, LuAG, YAG
and other materials may be doped with various materials including
for example Ce, Eu, etc. The specific components and/or formulation
of the phosphor and/or matrix material are not limitations of the
present invention.
[0013] The binder may also be referred to as an encapsulant or a
matrix material. In one embodiment, the binder includes or consists
essentially of a transparent material, for example silicone-based
materials or epoxy, having an index of refraction greater than
1.35. In one embodiment the binder and/or phosphor includes or
consists essentially of other materials, for example fumed silica
or alumina, to achieve other properties, for example to scatter
light, or to reduce settling of the powder in the binder. An
example of the binder material includes materials from the ASP
series of silicone phenyls manufactured by Shin Etsu, or the
Sylgard series manufactured by Dow Corning.
[0014] Herein, two components such as light-emitting elements
and/or optical elements being "aligned" or "associated" with each
other may refer to such components being mechanically and/or
optically aligned. By "mechanically aligned" is meant coaxial or
situated along a parallel axis. By "optically aligned" is meant
that at least some light (or other electromagnetic signal) emitted
by or passing through one component passes through and/or is
emitted by the other.
[0015] In an aspect, embodiments of the invention feature a method
of forming a composite wafer comprising a plurality of discrete
semiconductor dies suspended in a cured binder. The plurality of
discrete semiconductor dies is disposed on a mold substrate, and
each semiconductor die has at least two spaced-apart contacts
adjacent the mold substrate. The semiconductor dies are coated with
a binder, and the binder is cured to form the composite wafer. The
contacts of each semiconductor die remain at least partially
uncoated by the binder.
[0016] Embodiments of the invention may include one or more of the
following in any of a variety of combinations. The composite wafer
may be separated into a plurality of discrete portions each
including or consisting essentially of at least one semiconductor
die coated with cured binder. After separation the volume of binder
surrounding each semiconductor die may be substantially equal.
After separation the thickness of binder adjacent each
semiconductor die may be in the range of about 10 .mu.m to about
5000 .mu.m. Separating the composite wafer may include or consist
essentially of laser cutting, knife cutting, rotary knife cutting,
shearing, waterjet cutting, abrasive waterjet cutting, die cutting,
and/or sawing. Each discrete portion of the composite wafer may
contain only one semiconductor die. Each discrete portion of the
composite wafer may be a rectangular solid having approximately
90.degree. corners between adjacent faces thereof. After formation
of the composite wafer, at least some of the semiconductor dies may
be electrically tested, and the separated portions may be binned
based on the electrical testing. The contacts of the at least one
semiconductor die in one of the discrete portions may be
electrically coupled to spaced-apart conductive traces on a
substrate. For example, the contacts may be adhered to the
conductive traces with a conductive adhesive, wire bonding, and/or
soldering. The conductive adhesive may include or consist
essentially of a substantially isotropic conductive adhesive
electrically connecting a first contact only to a first trace and a
second contact only to a second trace, and a non-conductive
adhesive material may be provided in a gap between the conductive
traces. The conductive adhesive may include or consist essentially
of an anisotropic conductive adhesive (ACA) electrically connecting
a first contact only to a first trace and a second contact only to
a second trace. A portion of the ACA may be disposed in a gap
between the first and second contacts and may substantially isolate
the first contact from the second contact. The conductive traces
may include or consist essentially of silver, gold, aluminum,
chromium, copper, and/or carbon. The substrate may include or
consist essentially of polyethylene naphthalate, polyethylene
terephthalate, polycarbonate, polyethersulfone, polyester,
polyimide, polyethylene, and/or paper. The at least one
semiconductor die may include or consist essentially of a
light-emitting element. The reflectivity or the transmissivity of
the substrate for a wavelength emitted by the light-emitting
element and/or the cured phosphor may be greater than 80%. The at
least one semiconductor die may be electrically connected to
circuitry for powering the at least one semiconductor die. After
separating the composite wafer, additional material may be removed
from each of the discrete portions, whereby each portion has a
desired shape thereafter. The desired shapes may all be
substantially the same.
[0017] The composite wafer may be separated from the mold
substrate. A second substrate may be disposed in contact with the
plurality of semiconductor dies coated with binder, and the mold
substrate may be removed from the plurality of semiconductor dies
coated with binder, the plurality of semiconductor dies coated with
binder remaining attached to the second substrate. The composite
wafer may be separated from the second substrate. Before curing the
binder, the contacts of the plurality of semiconductor dies may be
at least partially embedded within the mold substrate, e.g., by at
least 2 .mu.m. After curing the binder, at least a portion of each
of the contacts of the plurality of semiconductor dies may protrude
from the cured binder. After curing the binder, at least a portion
of each semiconductor die proximate the contacts thereof may
protrude from the cured binder. After curing the binder, at least
one contact of at least one semiconductor die may not protrude from
the cured binder. The contacts of each semiconductor die remain
substantially entirely uncoated by binder. The binder may include
or consist essentially of silicone and/or epoxy.
[0018] Coating the plurality of semiconductor dies with the binder
may include or consist essentially of dispensing the binder into a
mold and disposing the mold substrate over the mold, whereby the
plurality of semiconductor dies are suspended within the binder.
Curing the binder may include or consist essentially of at least
partially curing the binder and, thereafter, removing the mold
substrate from the mold. The surface of the mold opposite the mold
substrate may have a texture (e.g., one configured to enhance light
extraction from the cured binder), and at least a portion of the
cured binder have the texture after the mold substrate is removed
from the mold. A texture for enhancing light extraction from the
cured binder may be applied to at least a portion of a surface of
the binder opposite the mold substrate after removing the mold
substrate from the mold. The mold may include or consist
essentially of a plurality of discrete compartments in which the
binder is disposed, and one or more semiconductor dies may be
suspended within or above each compartment prior to curing the
binder. Each compartment may impart a complementary shape to a
portion of the binder, the complementary shapes being substantially
identical to each other. The mold substrate may define one or more
openings therethrough. At least a portion of the binder may be
dispensed into the mold through at least one said opening. A
portion of the binder may flow through at least one said opening
when the mold substrate is disposed over the mold.
[0019] Coating the plurality of semiconductor dies with the binder
may include or consist essentially of dispensing the binder over
the mold substrate, the binder being contained over the mold
substrate by one or more barriers extending above a surface of the
mold substrate. A texture for enhancing light extraction from the
cured binder may be applied to at least a portion of a surface of
the binder opposite the mold substrate, whereby the cured binder
retains the texture. Curing the binder may include or consist
essentially of at least partially curing the binder and,
thereafter, removing the mold substrate from the plurality of
semiconductor dies. A mold cover may be disposed over and in
contact with at least a portion of the binder. The mold cover may
include or consist essentially of a plurality of discrete
compartments, and one or more semiconductor dies may be suspended
within or beneath each compartment prior to curing the binder. Each
compartment may impart a complementary shape to a portion of the
binder, the complementary shapes being substantially identical to
each other. The binder may contain a wavelength-conversion
material, e.g., a phosphor and/or quantum dots. Each semiconductor
die may include or consist essentially of a light-emitting
semiconductor die (e.g., a bare-die light-emitting diode). The
binder may be transparent to a wavelength of light emitted by the
light-emitting semiconductor dies. The light-emitting semiconductor
dies may each include or consist essentially of a semiconductor
material including or consisting essentially of GaAs, AlAs, InAs,
GaP, AlP, InP, ZnO, CdSe, CdTe, ZnTe, GaN, AlN, InN, silicon,
and/or an alloy or mixture thereof. The binder may contain a
wavelength-conversion material for absorption of at least a portion
of light emitted from the light-emitting semiconductor dies and
emission of converted light having a different wavelength,
converted light and unconverted light emitted by the light-emitting
semiconductor dies combining to form substantially white light. The
substantially white light may have a correlated color temperature
in the range of 2000 K to 10,000 K. The substantially white light
may have a color temperature variation less than four, or even less
than two, MacAdam ellipses across the composite wafer.
[0020] The composite wafer may have a first surface and a second
surface opposite the first surface, and the first and second
surface may be substantially flat and parallel. The composite wafer
may have a substantially uniform thickness with a thickness
variation less than 15%, less than 10%, or even less than 5%. The
composite wafer may have a substantially uniform thickness between
5 .mu.m and 4000 .mu.m. A dimension of the composite wafer
perpendicular to the thickness may be between 5 mm and 1000 mm. The
spacing between neighboring semiconductor dies may be substantially
constant across the composite wafer. The spacing may be in the
range of about 25 .mu.m to about 10,000 .mu.m. The thickness of the
binder above each of the semiconductor dies may be substantially
the same. The thickness of the binder above each of the
semiconductor dies may be in the range of about 25 .mu.m to about
4000 .mu.m. The thickness of the binder above each of the
semiconductor dies may be the same to within 5%. The plurality of
semiconductor dies may include or consist essentially of at least
100, at least 1000, or even at least 4000 semiconductor dies. The
semiconductor dies may be arranged in an array having substantially
equal distances between semiconductor dies in at least a first
direction. The array may have substantially equal distances between
semiconductor dies in at least a second direction different from
the first direction. The semiconductor dies may be arranged in a
regular periodic array. a release material (e.g., a mold-release
film) may be disposed over at least a portion of the binder. The
mold release film may be textured with a texture for enhancing
light extraction from the cured binder. The mold substrate may
include or consist essentially of glass, metal, silicone,
fiberglass, ceramic, water-soluble tape, thermal-release tape,
UV-release tape, polyethylene terephthalate, polyethylene
naphthalate, plastic film, tape, adhesive, acrylic, polycarbonate,
a polymer, and/or polytetrafluoroethylene. Curing the binder may
include or consist essentially of exposure to heat, air, moisture,
superatmospheric pressure, and/or ultraviolet radiation. Disposing
the plurality of discrete semiconductor dies on the mold substrate
may include or consist essentially of application of (i) an
adhesive force, (ii) a magnetic force, and/or (iii) vacuum. Prior
to disposing the plurality of discrete semiconductor dies on the
mold substrate, a group of semiconductor dies may be tested to
identify semiconductor dies having substantially equal
characteristics, and the plurality of semiconductor dies may be
selected from the identified semiconductor dies.
[0021] Prior to coating the plurality of semiconductor dies with
the binder, a stencil defining openings corresponding to positions
of the semiconductor dies may be disposed over the mold substrate.
The stencil may have a thickness in the range of about 0.5 .mu.m to
about 25 .mu.m. The stencil may include or consist essentially of a
flexible foil and/or a thin plate. The plurality of semiconductor
dies may be disposed within indentations in the mold substrate. The
indentations may have a depth in the range of about 0.5 .mu.m to
about 25 .mu.m. The mold substrate may include or consist
essentially of a vacuum chuck and/or an electrostatic chuck, and
the positions of the semiconductor dies may be maintained at least
in part by vacuum or electrostatic force. After the composite wafer
is formed, the vacuum or electrostatic force may be removed, and,
thereafter, the composite wafer may be removed from the mold
substrate. Coating the plurality of semiconductor dies with the
binder may include or consist essentially of controlling the amount
of binder dispensed over the semiconductor dies in response to a
feedback signal. The composite wafer may be removed from the mold
substrate by exposure to heat and/or ultraviolet radiation. The
binder may contain fumed silica, fumed alumina, and/or TiO.sub.2.
The binder may contain at least one additive for controlling
particle settling and/or controlling binder viscosity. The binder
may comprise a plurality of discrete regions, at least one of which
includes or consists essentially of the binder and at least one
wavelength-conversion material. At least one of the regions may
consist essentially of only the binder. At least one semiconductor
die may include or consist essentially of one or more active layers
over a substrate, and the substrate may be partially or completely
removed before coating with the binder. The substrate of the at
least one semiconductor die may be partially or completely removed
after disposing the at least one semiconductor die on the mold
substrate. Each of the semiconductor dies may include or consist
essentially of a light-detecting semiconductor die (e.g., a die in
which charge is formed in response to incipient light such as a
photovoltaic die). The binder may be transparent to a wavelength of
light detected by (i.e., resulting in charge formation in) the
light-detecting semiconductor dies. The light-detecting
semiconductor dies may include or consist essentially of a
semiconductor material including or consisting essentially of GaAs,
AlAs, InAs, GaP, AlP, InP, ZnO, CdSe, CdTe, ZnTe, GaN, AlN, InN,
silicon, and/or an alloy or mixture thereof. The binder may contain
a wavelength-conversion material for absorption of at least a
portion of light incident thereon and emission of converted light
(i) having a different wavelength and (ii) for detection by the
light-detecting semiconductor die.
[0022] An optical element may be associated with (e.g., aligned to)
one or more of the semiconductor dies. An array of optical elements
may be disposed on the binder prior to curing. Curing the binder
may adhere the array of optical elements to the cured binder. The
composite wafer may include the array of optical elements, and the
composite wafer may be separated into discrete portions each
including at least one optical element. The plurality of
semiconductor dies may include a light-emitting semiconductor die
and/or a light-detecting semiconductor die. A reflecting layer
(e.g., a reflecting film) may be formed over or within at least a
portion of the composite wafer (e.g., over or within the binder).
The reflecting film may include or consist essentially of aluminum,
copper, gold, silver, and/or titanium. The reflecting layer may
include or consist essentially of a plurality of particles (e.g.,
fumed silica particles, fumed alumina particles, and/or TiO.sub.2
particles). Forming the reflecting layer may include or consist
essentially of disposing the plurality of particles over the mold
substrate and plurality of semiconductor dies before coating the
plurality of semiconductor dies with the binder. Prior to coating
the plurality of semiconductor dies with the binder, a reflecting
film defining openings corresponding to positions of the
semiconductor dies may be disposed over the mold substrate. The
semiconductor die may include or consist essentially of a
light-emitting or a light-detecting semiconductor die, and a
reflecting layer may be formed over at least a portion of the
surface of the composite wafer, the reflecting layer having a
reflectivity of at least 25% to a wavelength of light emitted or
absorbed by (i) the semiconductor die and/or (ii) the binder.
[0023] In another aspect, embodiments of the invention feature a
method of forming a composite wafer comprising a plurality of
discrete semiconductor dies suspended in a cured binder. The
plurality of discrete semiconductor dies are disposed on a mold
substrate, and each semiconductor die has at least two spaced-apart
contacts opposite the mold substrate. The plurality of
semiconductor dies are coated with a first binder, the contacts of
each semiconductor die remaining at least partially uncoated. The
first binder is at least partially cured. A second substrate is
disposed in contact with the plurality of semiconductor dies coated
with at least partially cured first binder. Thereafter, the mold
substrate is removed from the plurality of semiconductor dies,
thereby exposing a portion of each semiconductor die uncoated by
the first binder, the plurality of semiconductor dies remaining
attached to the second substrate. At least the uncoated portion of
each of the plurality of semiconductor dies is coated with a second
binder, and the contacts of each semiconductor die remain at least
partially uncoated. The second binder is cured to form the
composite wafer.
[0024] Embodiments of the invention may include one or more of the
following in any of a variety of combinations. The first binder and
the second binder may include or consist essentially of the same
material. The composite wafer may be separated into a plurality of
discrete portions each including at least one semiconductor die
coated with cured first binder and cured second binder. The
composite wafer may be separated from the second substrate. At
least a portion of each of the contacts of the plurality of
semiconductor dies of the composite wafer may protrude from cured
first binder and/or cured second binder. At least a portion of each
semiconductor die proximate the contacts thereof may protrude from
cured first binder and/or cured second binder. The first binder
and/or the second binder may include or consist essentially of
silicone and/or epoxy. Coating at least the uncoated portion of
each of the plurality of semiconductor dies with the second binder
may include or consist essentially of dispensing the second binder
into a mold and disposing the mold substrate over the mold, whereby
the plurality of semiconductor dies are disposed in contact with
the second binder. Curing the second binder may include or consist
essentially of at least partially curing the second binder and,
thereafter, removing the mold substrate from the mold. A surface of
the mold opposite the mold substrate may have a texture (e.g., a
texture configured to enhance light extraction from the cured
second binder), and at least a portion of the cured second binder
may have the texture after the mold substrate is removed from the
mold. A texture for enhancing light extraction from the cured
second binder may be applied to at least a portion of a surface of
the second binder opposite the mold substrate after removing the
mold substrate from the mold. The mold may include or consist
essentially of a plurality of discrete compartments in which the
second binder is disposed, and (ii) one or more semiconductor dies
may be suspended within or above each compartment prior to curing
the second binder. Each compartment may impart a complementary
shape to a portion of the second binder, the complementary shapes
being substantially identical to each other.
[0025] Coating at least the uncoated portion of each of the
plurality of semiconductor dies with the second binder may include
or consist essentially of dispensing the second binder over the
mold substrate, and the second binder may be contained over the
mold substrate by one or more barriers extending above a surface of
the mold substrate. A texture for enhancing light extraction from
the cured second binder may be applied to at least a portion of a
surface of the second binder opposite the mold substrate, whereby
the cured second binder retains the texture. Curing the second
binder may include or consist essentially of at least partially
curing the second binder and, thereafter, removing the mold
substrate from the plurality of semiconductor dies. A mold cover
may be disposed over and in contact with at least a portion of the
second binder. The mold cover may include or consist essentially of
a plurality of discrete compartments, and one or more semiconductor
dies may be suspended within or beneath each compartment prior to
curing the second binder. Each compartment may impart a
complementary shape to a portion of the second binder, the
complementary shapes being substantially identical to each other.
The first binder and/or the second binder may contain a
wavelength-conversion material (e.g., a phosphor and/or quantum
dots). Each semiconductor die may include or consist essentially of
a light-emitting semiconductor die (e.g., a bare-die light-emitting
diode). The first binder and/or the second binder may be
transparent to a wavelength of light emitted by the light-emitting
semiconductor dies. Each light-emitting semiconductor die may
include or consist essentially of a semiconductor material
including or consisting essentially of GaAs, AlAs, InAs, GaP, AlP,
InP, ZnO, CdSe, CdTe, ZnTe, GaN, AlN, InN, silicon, and/or an alloy
or mixture thereof. The first binder and/or the second binder may
contain a wavelength-conversion material for absorption of at least
a portion of light emitted from the light-emitting semiconductor
dies and emission of converted light having a different wavelength,
converted light and unconverted light emitted by the light-emitting
semiconductor dies combining to form substantially white light. The
substantially white light may have a correlated color temperature
in the range of 2000 K to 10,000 K. The substantially white light
may have a color temperature variation less than four, or even less
than two, MacAdam ellipses across the composite wafer.
[0026] In yet another aspect, embodiments of the invention feature
a method of forming electronic devices. A plurality of discrete
semiconductor dies is disposed on a mold substrate, each
semiconductor die having at least two spaced-apart contacts
adjacent the mold substrate. The plurality of semiconductor dies is
coated with a binder. The binder is cured to form a composite wafer
including or consisting essentially of the plurality of
semiconductor dies suspended in the cured binder, the contacts of
each semiconductor die remaining at least partially uncoated with
binder. The composite wafer is separated into a plurality of
discrete portions each including or consisting essentially of at
least one semiconductor die suspended in cured binder. Thereafter,
the discrete portions of the composite wafer are removed from the
mold substrate.
[0027] Embodiments of the invention may include one or more of the
following in any of a variety of combinations. The binder may
include or consist essentially of (i) silicone and/or epoxy and
(ii) a wavelength-conversion material, and each of the
semiconductor dies may include or consist essentially of a
light-emitting diode. The wavelength-conversion material may absorb
at least a portion of light emitted from a light-emitting
semiconductor die and emit converted light having a different
wavelength, converted light and unconverted light emitted by the
light-emitting semiconductor die combining to form substantially
white light. After curing the binder, at least a portion of each of
the contacts of the plurality of semiconductor dies may protrude
from the cured binder. After curing the binder, at least a portion
of each semiconductor die proximate the contacts thereof may
protrude from the cured binder.
[0028] In an additional aspect, embodiments of the invention
feature a method of forming electronic devices. A plurality of
discrete semiconductor dies is disposed on a mold substrate, each
semiconductor die having at least two spaced-apart contacts
opposite the mold substrate. The plurality of semiconductor dies is
coated with a first binder, the contacts of each semiconductor die
remaining at least partially uncoated. The first binder is at least
partially cured. A second substrate is disposed in contact with the
plurality of semiconductor dies coated with at least partially
cured first binder. Thereafter, the mold substrate is removed from
the plurality of semiconductor dies, thereby exposing a portion of
each semiconductor die uncoated by the first binder, the plurality
of semiconductor dies remaining attached to the second substrate.
At least the uncoated portion of each of the plurality of
semiconductor dies is coated with a second binder. The second
binder is cured to form a composite wafer including or consisting
essentially of the plurality of semiconductor dies and cured first
and second binders. The composite wafer is separated into a
plurality of discrete portions each including or consisting
essentially of at least one semiconductor die and cured first and
second binders. Thereafter, the discrete portions of the composite
wafer are removed from the mold substrate.
[0029] Embodiments of the invention may include one or more of the
following in any of a variety of combinations. The first binder and
the second binder may include or consist essentially of the same
material. The first binder and/or the second may include or consist
essentially of (i) silicone and/or epoxy and (ii) a
wavelength-conversion material, and each of the semiconductor dies
may include or consist essentially of a light-emitting diode. The
wavelength-conversion material may absorb at least a portion of
light emitted from a light-emitting semiconductor die and emit
converted light having a different wavelength, converted light and
unconverted light emitted by the light-emitting semiconductor die
combining to form substantially white light. After curing the
second binder, at least a portion of each of the contacts of the
plurality of semiconductor dies may protrude from the cured first
binder and/or the cured second binder (i.e., from the composite
wafer). After curing the second binder, at least a portion of each
semiconductor die proximate the contacts thereof may protrude from
the cured first binder and/or the cured second binder.
[0030] In yet an additional aspect, embodiments of the invention
feature a method of forming a composite wafer including or
consisting essentially of a plurality of discrete semiconductor
dies suspended in a cured binder. The plurality of discrete
semiconductor dies is disposed on a mold substrate, each
semiconductor die having at least two spaced-apart contacts. The
plurality of semiconductor dies is coated with a binder. The binder
is cured to form the composite wafer. At least a portion of the
binder proximate the at least two contacts is removed to expose at
least portions of each of the at least two contacts. The composite
wafer may be separated into a plurality of discrete portions each
including or consisting essentially of at least one semiconductor
die suspended in cured binder. Thereafter, the discrete portions of
the composite wafer may be removed from the mold substrate.
[0031] In an aspect, embodiments of the invention feature an
electronic device including or consisting essentially of a solid
shaped volume of a polymeric binder and, suspended within the
binder, a semiconductor die having a first face, a second face
opposite the first face, at least one sidewall spanning the first
and second faces. At least two spaced-apart contacts are disposed
on the first face of the semiconductor die. The contacts each have
a free terminal end (i) not covered by the binder and (ii)
available for electrical connection. Embodiments of the invention
may include one or more of the following in any of a variety of
combinations. At least portions of the contacts may protrude from
the binder. At least a portion of each said sidewall may protrude
from the binder. The binder may define a rectangular solid having
approximately 90.degree. corners between adjacent faces thereof.
The binder may include or consist essentially of silicone and/or
epoxy. One or more additional semiconductor dies may be suspended
within the binder. The binder may contain a wavelength-conversion
material (e.g., a phosphor and/or quantum dots) therein. The
semiconductor die may include or consist essentially of a
light-emitting element (e.g., a bare-die light-emitting diode). The
binder may be transparent to a wavelength of light emitted by the
light-emitting element. The light-emitting element may include or
consist essentially of a semiconductor material including or
consisting essentially of GaAs, AlAs, InAs, GaP, AlP, InP, ZnO,
CdSe, CdTe, ZnTe, GaN, AlN, InN, silicon, and/or an alloy or
mixture thereof. The binder may contain a wavelength-conversion
material for absorption of at least a portion of light emitted from
the light-emitting element and emission of converted light having a
different wavelength, converted light and unconverted light emitted
by the light-emitting element combining to form substantially white
light. The substantially white light may have a correlated color
temperature in the range of 2000 K to 10,000 K. The binder may have
a thickness between 5 .mu.m and 4000 .mu.m. A dimension of the
binder perpendicular to the thickness may be between 25 .mu.m and
50 mm. At least a portion of the surface of the binder may have a
texture for enhancing extraction of light from the binder.
[0032] The semiconductor die may include or consist essentially of
a light-detecting element. The binder may be transparent to a
wavelength of light detected by the light-detecting element. An
optical element may be positioned to receive light from or transmit
light to the semiconductor die. A reflecting layer may be disposed
over or within at least a portion of the binder. The reflecting
layer may include or consist essentially of (i) a reflecting film
and/or (ii) a plurality of particles. The semiconductor die may
include or consist essentially of a light-emitting element or a
light-detecting element, and the reflecting layer may have a
reflectivity of at least 25% to a wavelength of light (i) emitted
or detected by the semiconductor die or (ii) emitted by the binder.
The binder may include or consist essentially of a plurality of
discrete regions, at least one of which includes or consists
essentially of the binder and at least one wavelength-conversion
material. Another of the regions may consist essentially of only
the binder. The semiconductor die may include or consist
essentially of one or more active semiconductor layers not disposed
on a semiconductor substrate. One or more alignment marks may be
disposed on the surface of the binder for alignment and/or
orientation of the semiconductor die.
[0033] In another aspect, embodiments of the invention feature a
composite wafer including or consisting essentially of a solid
volume of a polymeric binder having a first surface and a second
surface opposite the first surface and, suspended within the
binder, a plurality of semiconductor dies each having a first face,
a second face opposite the first face, and at least one sidewall
spanning the first and second faces. At least two spaced-apart
contacts are disposed on the first face of each semiconductor die.
The contacts each have a free terminal end (i) not covered by the
binder and (ii) available for electrical connection.
[0034] Embodiments of the invention may include one or more of the
following in any of a variety of combinations. At least portions of
the contacts of the semiconductor dies may protrude from the
binder. At least a portion of each said sidewall of each of the
semiconductor dies may protrude from the first surface of the
binder. The binder may include or consist essentially of silicone
and/or epoxy. The binder may contain a wavelength-conversion
material (e.g., a phosphor and/or quantum dots) therein. Each
semiconductor die may include or consist essentially of a
light-emitting element (e.g., a bare-die light-emitting diode). The
binder may be transparent to a wavelength of light emitted by the
semiconductor dies. Each semiconductor die may include or consist
essentially of a semiconductor material that includes or consists
essential of GaAs, AlAs, InAs, GaP, AlP, InP, ZnO, CdSe, CdTe,
ZnTe, GaN, AlN, InN, silicon, and/or an alloy or mixture thereof.
The binder may contain a wavelength-conversion material for
absorption of at least a portion of light emitted from the
light-emitting elements and emission of converted light having a
different wavelength, converted light and unconverted light emitted
by the light-emitting elements combining to form substantially
white light. The substantially white light may have a correlated
color temperature in the range of 2000 K to 10,000 K. The
substantially white light may have a variation in color temperature
of less than four, or even less than two, MacAdam ellipses across
the composite wafer. The first and second surfaces of the binder
may be substantially flat and parallel. The binder may have a
substantially uniform thickness with a thickness variation less
than 10%, or even less than 5%. The binder may have a thickness
between 15 .mu.am and 4000 .mu.m. A dimension of the binder
perpendicular to the thickness (e.g., a side length or a diameter)
may be between 100 .mu.am and 1000 mm. The spacing between each
pair of the plurality of semiconductor dies may be substantially
the same. The spacing between each pair of the plurality of
semiconductor dies may be in the range of about 25 .mu.am to about
10,000 .mu.m. The thickness of the binder above each of the
plurality of semiconductor dies may be substantially the same. The
thickness of the binder above each of the plurality of
semiconductor dies may be the same to within 5%.
[0035] The plurality of semiconductor dies may include or consist
essentially of at least 500 semiconductor dies, or even at least
2000 semiconductor dies. The semiconductor dies may be arranged in
an array having substantially equal distances between semiconductor
dies in at least a first direction. The array of semiconductor dies
may have substantially equal distances between semiconductor dies
in a second direction different from the first direction. The
semiconductor dies may be arranged in a regular periodic (e.g.,
two-dimensional) array. At least a portion of the surface of the
binder may be textured with a texture for enhancing light
extraction from the binder. Each semiconductor die may include or
consist essentially of a light-detecting element (e.g., a
photovoltaic die). The binder may be transparent to a wavelength of
light detected by the semiconductor dies. At least one optical
element may be positioned to receive light from or transmit light
to at least one of the semiconductor dies. The at least one optical
element may include or consist essentially of a plurality of
discrete optical elements each associated with at least one
semiconductor die. A reflecting layer (e.g., a reflecting film
and/or a plurality of particles) may be disposed over or within at
least a portion of the binder. Each semiconductor die may include
or consist essentially of a light-emitting element or a
light-detecting element, and the reflecting layer may have a
reflectivity of at least 25% to a wavelength of light (i) emitted
or detected by the semiconductor dies or (ii) emitted by the
binder. The binder may include or consist essentially of a
plurality of discrete regions, at least one of which comprises the
binder and at least one wavelength-conversion material. At least
one other region may consist essentially of the binder. Each
semiconductor die may include or consist essentially of one or more
active semiconductor layers not disposed on a semiconductor
substrate. One or more alignment marks may be disposed on the first
surface or the second surface of the binder. The binder may include
or consist essentially of a plurality of shaped regions, each
shaped region (i) associated with at least one semiconductor die
and (ii) having a shape substantially identical to shapes of the
other shaped regions.
[0036] In yet another aspect, embodiments of the invention feature
an electronic device including or consisting essentially of (i) a
substrate having first and second conductive traces thereon, the
first and second conductive traces being separated on the substrate
by a gap therebetween, (ii) disposed over the gap, a semiconductor
die having a first face, a second face opposite the first face, at
least one sidewall spanning the first and second faces, and two
spaced-apart contacts on the first face, the contacts each being
electrically coupled to a different conductive trace, and (iii)
encasing the second face and at least a portion of each said
sidewall of the semiconductor die, a solid polymeric binder
defining a rectangular solid having approximately 90.degree.
corners between adjacent faces thereof. At least a portion of each
of the contacts is not covered by the binder.
[0037] Embodiments of the invention may include one or more of the
following in any of a variety of combinations. At least a portion
of each of the contacts may protrude from the binder. At least a
portion of each said sidewall may protrude from the binder. The
binder may include or consist essentially of silicone and/or epoxy.
The binder may contain a wavelength-conversion material (e.g., a
phosphor and/or quantum dots) therein. The top surface of the
binder opposite the substrate may have a texture for promoting
light extraction from the top surface. The semiconductor die may
include or consist essentially of a light-emitting element (e.g., a
bare-die light-emitting diode). The binder may be transparent to a
wavelength of light emitted by the semiconductor die. The
semiconductor die may include or consist essentially of a
semiconductor material including or consisting essentially of GaAs,
AlAs, InAs, GaP, AlP, InP, ZnO, CdSe, CdTe, ZnTe, GaN, AlN, InN,
silicon, and/or an alloy or mixture thereof. The binder may contain
a wavelength-conversion material for absorption of at least a
portion of light emitted from the semiconductor die and emission of
converted light having a different wavelength, converted light and
unconverted light emitted by the semiconductor die combining to
form substantially white light. The substantially white light may
have a correlated color temperature in the range of 2000 K to
10,000 K.
[0038] The semiconductor die may include or consist essentially of
a light-detecting element. The binder may be transparent to a
wavelength of light detected by the semiconductor die. An optical
element may be associated with (e.g., aligned to) the semiconductor
die. A reflecting layer may be disposed over or within at least a
portion of the binder. The binder may include or consist
essentially of a plurality of discrete regions, at least one of
which includes or consists essentially of the binder and at least
one wavelength-conversion material. Another region may consist
essentially of the binder. The semiconductor die may include or
consist essentially of one or more active semiconductor layers not
disposed on a semiconductor substrate (i.e., no semiconductor
substrate is present within the die). The contacts may be
electrically coupled to the conductive traces with a conductive
adhesive. The conductive adhesive may include or consist
essentially of a substantially isotropic conductive adhesive
electrically connecting a first contact only to the first trace and
a second contact only to the second trace, and a non-conductive
adhesive material may be disposed in the gap. The conductive
adhesive comprises an anisotropic conductive adhesive (ACA)
electrically connecting a first contact only to the first trace and
a second contact only to the second trace. A portion of the ACA may
be disposed in the gap and may substantially isolate the first
contact from the second contact. The contacts may be electrically
coupled to the conductive traces by wire bonds and/or solder. The
conductive traces may include or consist essentially of silver,
gold, aluminum, chromium, copper, and/or carbon. The substrate may
include or consist essentially of polyethylene naphthalate,
polyethylene terephthalate, polycarbonate, polyethersulfone,
polyester, polyimide, polyethylene, and/or paper. The semiconductor
die may include or consist essentially of a light-emitting element.
The reflectivity of the substrate for a wavelength emitted by at
least one of the light-emitting element or the binder may be
greater than 80%. The transmissivity of the substrate for a
wavelength emitted by at least one of the light-emitting element or
the binder may be greater than 80%. Circuitry for powering the
semiconductor die may be electrically connected to the
semiconductor die.
[0039] These and other objects, along with advantages and features
of the invention, will become more apparent through reference to
the following description, the accompanying drawings, and the
claims. Furthermore, it is to be understood that the features of
the various embodiments described herein are not mutually exclusive
and can exist in various combinations and permutations. Reference
throughout this specification to "one example," "an example," "one
embodiment," or "an embodiment" means that a particular feature,
structure, or characteristic described in connection with the
example is included in at least one example of the present
technology. Thus, the occurrences of the phrases "in one example,"
"in an example," "one embodiment," or "an embodiment" in various
places throughout this specification are not necessarily all
referring to the same example. Furthermore, the particular
features, structures, routines, steps, or characteristics may be
combined in any suitable manner in one or more examples of the
technology. The term "light" broadly connotes any wavelength or
wavelength band in the electromagnetic spectrum, including, without
limitation, visible light, ultraviolet radiation, and infrared
radiation. Similarly, photometric terms such as "illuminance,"
"luminous flux," and "luminous intensity" extend to and include
their radiometric equivalents, such as "irradiance," "radiant
flux," and "radiant intensity." As used herein, the terms
"substantially," "approximately," and "about" mean.+-.10%, and in
some embodiments, .+-.5%. The term "consists essentially of" means
excluding other materials that contribute to function, unless
otherwise defined herein. Nonetheless, such other materials may be
present, collectively or individually, in trace amounts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] In the drawings, like reference characters generally refer
to the same parts throughout the different views. Also, the
drawings are not necessarily to scale, emphasis instead generally
being placed upon illustrating the principles of the invention. In
the following description, various embodiments of the present
invention are described with reference to the following drawings,
in which:
[0041] FIG. 1 is a graph of emission and excitation spectra of an
exemplary LED and phosphor;
[0042] FIGS. 2A and 2B are, respectively, cross-sectional and
bottom schematics of a white die in accordance with various
embodiments of the invention;
[0043] FIG. 3 is a flow chart of a technique for forming a white
die in accordance with various embodiments of the invention;
[0044] FIGS. 4A-4E are cross-sectional schematics of process steps
utilized to fabricate white dies in accordance with various
embodiments of the invention;
[0045] FIG. 5 is a cross-sectional schematic of a white die in
accordance with various embodiments of the invention;
[0046] FIG. 6 is a flow chart of a technique for fabricating binned
white dies having similar characteristics in accordance with
various embodiments of the invention;
[0047] FIG. 7 is a schematic illustration of binned white dies
having similar characteristics in accordance with various
embodiments of the invention;
[0048] FIGS. 8A-8D are cross-sectional schematics of process steps
utilized to fabricate white dies in accordance with various
embodiments of the invention;
[0049] FIGS. 9A-9F are cross-sectional schematics of white dies in
various stages of manufacture in accordance with various
embodiments of the invention;
[0050] FIGS. 10A-10D and 1 are cross-sectional schematics of
process steps utilized to fabricate white dies in accordance with
various embodiments of the invention;
[0051] FIGS. 12A-12F are cross-sectional schematics of white dies
in accordance with various embodiments of the invention;
[0052] FIGS. 13A-13G are cross-sectional schematics of process
steps utilized to fabricate white dies in accordance with various
embodiments of the invention;
[0053] FIGS. 14A-14C are cross-sectional schematics of white dies
in accordance with various embodiments of the invention;
[0054] FIGS. 15A-15E are cross-sectional schematics of process
steps utilized to fabricate white dies in accordance with various
embodiments of the invention;
[0055] FIGS. 15F and 15G are cross-sectional schematics of white
dies in accordance with various embodiments of the invention;
[0056] FIGS. 16A-16C are a schematic cross-sectional schematic
(FIG. 16A) and schematic bottom views (FIGS. 16B and 16C) of white
dies in accordance with various embodiments of the invention;
[0057] FIGS. 17A and 17B are, respectively, a cross-sectional
schematic and a plan-view schematic of a light-emitting element
utilized in white dies in accordance with various embodiments of
the invention;
[0058] FIG. 17C is a cross-sectional schematic of a light-emitting
element utilized in white dies in accordance with various
embodiments of the invention;
[0059] FIG. 18 is a cross-sectional schematic of a white die
incorporating the light-emitting element of FIGS. 17A and 17B;
[0060] FIG. 19 is a chromaticity diagram in accordance with various
embodiments of the invention;
[0061] FIG. 20 is a cross-sectional schematic of a
feedback-controlled phosphor dispensing system in accordance with
various embodiments of the invention;
[0062] FIGS. 21 and 22 are cross-sectional schematics of leveling
systems for the fabrication of planar white dies in accordance with
various embodiments of the invention;
[0063] FIGS. 23A and 23B are cross-sectional schematics of white
dies in accordance with various embodiments of the invention;
[0064] FIGS. 24A-24C are cross-sectional schematics of process
steps utilized to fabricate white dies in accordance with various
embodiments of the invention;
[0065] FIGS. 25 and 26 are cross-sectional schematics of white dies
in accordance with various embodiments of the invention;
[0066] FIG. 27 is a cross-sectional schematic of a lighting system
utilizing white dies in accordance with various embodiments of the
invention;
[0067] FIG. 28 is a plan-view schematic of a lighting system
utilizing white dies in accordance with various embodiments of the
invention;
[0068] FIG. 29 is a cross-sectional schematic of a tilted mold
utilized to fabricated white dies in accordance with various
embodiments of the invention;
[0069] FIG. 30 is a cross-sectional schematic of a system for
fabricating white dies with different thicknesses of phosphor with
feedback-based control in accordance with various embodiments of
the invention;
[0070] FIGS. 31A-31C are cross-sectional schematics of process
steps utilized to treat portions of a substrate for reduced
adhesion to phosphor in accordance with various embodiments of the
invention;
[0071] FIGS. 32A and 32B are cross-sectional schematics of process
steps utilized to fabricate white dies in accordance with various
embodiments of the invention;
[0072] FIGS. 33A and 33C are cross-sectional schematics of
structures formed during fabrication of white dies utilizing
release materials in accordance with various embodiments of the
invention;
[0073] FIGS. 33B and 33D are cross-sectional schematics of white
dies fabricated from the structures of FIGS. 33A and 33C,
respectively;
[0074] FIG. 34 is a cross-sectional schematic of light-emitting
elements on a substrate composed of materials having different
levels of adhesion in accordance with various embodiments of the
invention;
[0075] FIGS. 35A and 35B are cross-sectional schematics of
light-emitting elements disposed on compressible substrates in
accordance with various embodiments of the invention;
[0076] FIG. 36 is a cross-sectional schematic of light-emitting
elements on a substrate patterned to control die relief of white
dies incorporating the light-emitting elements in accordance with
various embodiments of the invention;
[0077] FIGS. 37 and 38 are cross-sectional schematics of
light-emitting elements on substrates with through-holes for
application of vacuum in accordance with various embodiments of the
invention;
[0078] FIGS. 39A and 39B are cross-sectional schematics of white
dies in accordance with various embodiments of the invention;
[0079] FIGS. 40A-40D are cross-sectional schematics of process
steps utilized to fabricate white dies in accordance with various
embodiments of the invention;
[0080] FIGS. 40E and 40F are cross-sectional schematics of white
dies each incorporating multiple light-emitting elements in
accordance with various embodiments of the invention;
[0081] FIGS. 41A and 41B are cross-sectional schematics of white
dies fabricated with a shaped blade in accordance with various
embodiments of the invention;
[0082] FIGS. 42A-42D are cross-sectional schematics of white dies
in accordance with various embodiments of the invention;
[0083] FIG. 43 is a cross-sectional schematic of a white die
incorporating a reflecting layer in accordance with various
embodiments of the invention;
[0084] FIG. 44 is a cross-sectional schematic of a processing step
utilized to fabricate the white die of FIG. 43 in accordance with
various embodiments of the invention;
[0085] FIGS. 45A-45C are cross-sectional schematics of process
steps utilized to fabricate white dies with reflecting films in
accordance with various embodiments of the invention;
[0086] FIGS. 46A-46C are cross-sectional schematics of white dies
incorporating optical elements in accordance with various
embodiments of the invention;
[0087] FIGS. 47A and 47B are cross-sectional schematics of process
steps utilized to fabricate the white die for FIG. 46A in
accordance with various embodiments of the invention;
[0088] FIG. 48 is a cross-sectional schematic of a processing step
utilized to couple optical elements to a white wafer of white dies
in accordance with embodiments of the invention;
[0089] FIGS. 49A-49E are cross-sectional schematics of clear dies
in accordance with various embodiments of the invention;
[0090] FIGS. 50 and 51 are cross-sectional schematics of lighting
devices incorporating white dies and optical elements in accordance
with various embodiments of the invention;
[0091] FIGS. 52 and 53 are cross-sectional schematics of components
of the lighting device of FIG. 51;
[0092] FIG. 54 is a cross-sectional schematic of a lighting device
incorporating white dies and optical elements in accordance with
various embodiments of the invention;
[0093] FIG. 55 is a cross-sectional schematic of a component of the
lighting device of FIG. 54;
[0094] FIG. 56 is a cross-sectional schematic of an optic utilized
in lighting devices in accordance with various embodiments of the
invention;
[0095] FIG. 57 is a cross-sectional schematic of a lighting device
incorporating the optic of FIG. 56 in accordance with various
embodiments of the invention;
[0096] FIGS. 58A-58C are cross-sectional schematics of
light-detecting devices in accordance with various embodiments of
the invention;
[0097] FIGS. 59A and 59B are cross-sectional schematics of
photovoltaic devices in accordance with various embodiments of the
invention;
[0098] FIGS. 60A-60E are cross-sectional schematics of electronic
devices in accordance with various embodiments of the invention;
and
[0099] FIGS. 61 and 62 are cross-sectional schematics of packaged
systems incorporating multiple devices in accordance with various
embodiments of the invention.
DETAILED DESCRIPTION
[0100] Embodiments of the present invention provide a new approach
to integration of phosphor and light-emitting elements, such as LED
dies, that addresses a number of the deficiencies and difficulties
present in the current manufacture of white packaged LEDs.
Advantageously, the phosphor may be integrated with a die before it
is placed in a package (or instead of being conventionally
packaged), thereby producing a package-free white die. An example
is depicted as white die 200 in FIG. 2A. White die 200 includes one
or more LEEs 210, each of which features at least one contact 220.
As shown, the LEE 210 is partially surrounded by a phosphor 230. At
least a portion of contact(s) 220 is typically not covered by
phosphor 230. In the configuration shown in FIG. 2A, LEE 210
features two contacts 220 that are situated on the same face or
side 240 of LEE 210. As shown, each of the contacts 220 preferably
has a free terminal end that is not covered by the phosphor 230 and
that is available for electrical connection. Herein, "available for
electrical connection" means the contact has sufficient free area
to permit attachment to, e.g., a conductive trace, a circuit board,
etc, and "free" means lacking any electrical connection (and in
preferred embodiments, any mechanical connection) thereto.
[0101] While face 240 of LEE 210 is shown as being a single planar
surface, this is not a limitation of the present invention, and in
other embodiments face 240 is composed of multiple non-coplanar
surfaces or may have other configurations. In some embodiments LEE
210 has more than two contacts 220. White die 200 is shown in FIG.
2A as having no phosphor 230 covering face 240; however, this is
not a limitation of the present invention, and in other embodiments
phosphor 230 covers all or a portion of face 240. As discussed
above, here phosphor may refer to a binder or matrix material alone
or a mixture of the binder and wavelength-conversion material. In
FIG. 2A, the width of phosphor 230 around the sides of LEE 210 is
identified as a width 250, while the thickness of phosphor 230 over
LEE 210 is identified as a thickness 260 and the thickness of
phosphor 230 adjacent to LEE 210 is identified as a thickness
270.
[0102] FIGS. 2A and 2B show white die 200 including one LEE 210;
however, this is not a limitation of the present invention, and in
other embodiments white die 200 includes more than one LEE 210. In
some embodiments, multiple LEEs 210 of a single white die 200 are
all the same, while in other embodiments they are made up of at
least two different types of LEE 210. In one embodiment, different
types of LEE 210 emit at different wavelengths. For example, white
die 200 may include one or more of each of three different types of
LEE 210, where at least one type emits in the blue wavelength
range, at least one in the green wavelength range and at least one
in the red wavelength range. In one embodiment white die 200 may
include one or more of each of two different types of LEE 210,
where at least one type emits in the blue wavelength range and at
least one in the red wavelength range. The specific configuration
of the LEE 210 in white die 200 as well as their operating
characteristics and properties are not a limitation of the present
invention. In one embodiment, different types of LEE 210 have
different light output powers. In one embodiment, phosphor 230 may
be composed of a plurality of portions or volumes, where each
portion or volume includes or consists essentially of one or more
phosphors different from one or more phosphors in another portion.
In one embodiment of this example, one or more portions include or
consist essentially of only a transparent binder material, while
one or more other portions include or consist essentially of a
binder and one or more phosphors.
[0103] In some embodiments, a surface 280 of phosphor 230 is
parallel or substantially parallel to a surface 242 of LEE 210. In
some embodiments, a surface 290 of phosphor 230 is parallel or
substantially parallel to a surface 244 of LEE 210. In some
embodiments phosphor 230 forms a substantially cubic or
rectangular-solid shape (the contour of which may be broken by
portions of the LEE 210 and/or the contacts of the LEE 210). The
thickness 260 of phosphor 230 over LEE 210 is shown as the same or
substantially the same over the entirety of LEE 210; however, this
is not a limitation of the present invention and in other
embodiments thickness 260 of phosphor 230 over LEE 210 varies. The
thickness 270 of phosphor 230 adjacent to LEE 210 is shown as the
same or substantially the same for white die 200; however, this is
not a limitation of the present invention and in other embodiments
thickness 270 of phosphor 230 adjacent to LEE 210 varies. FIG. 2A
shows surface 280 and side surfaces 290 of phosphor 230 as flat or
substantially flat; however, this is not a limitation of the
present invention and in other embodiments surface 280 and/or
surface 290 are curved, roughened, patterned, or textured in a
regular, periodic, or random pattern. In some embodiments phosphor
230 has, at least in part, a smooth, substantially continuous
shape. In some embodiments, shaping and/or patterning or texturing
of the surface is achieved during the formation or molding process,
while in other embodiments shaping and/or patterning or texturing
is performed after the phosphor is molded or after it is cured or
partially cured.
[0104] FIG. 2B shows a view of the white die 200 facing the contact
side of LEE 210. LEE 210 in FIG. 2B is shown as rectangular in
cross-section, but this is not a limitation of the present
invention and in other embodiments LEE 210 is square, hexagonal,
circular, triangular or any arbitrary shape and/or may have
sidewalls forming any angle with respect to the surface 280 of
white die 200. In FIG. 2B width 250 of phosphor 230 on the sides of
LEE 210 is shown as the same or substantially the same on all sides
of LEE 210; however, this is not a limitation of the present
invention and in other embodiments width 250 of phosphor 230 is
different on one or more or all sides of LEE 210. FIG. 2B shows
width 250 of phosphor 230 as the same or substantially the same
across each side of LEE 210; however, this is not a limitation of
the present invention, and in other embodiments width 250 of
phosphor 230 varies along one or more sides of LEE 210.
[0105] As discussed above, embodiments of the present invention
form phosphor 230 on LEE 210 prior to attachment (electrical and/or
mechanical) to a package or to a substrate. White die 200 may then
be integrated in a variety of packages, as discussed below. FIG. 3
shows a flow chart of a process 300 for forming white die 200.
Process 300 is shown having six steps; however, this is not a
limitation of the present invention and in other embodiments the
invention has more or fewer steps and/or the steps may be performed
in different order. In step 310, a first surface or base is
provided. In step 320, one or more LEEs are placed or formed on the
base. In step 330, the phosphor is provided. In step 340, the
phosphor is formed over the LEE and base. In step 350, the phosphor
is cured. In step 360, the phosphor-coated LEEs are separated or
singulated into white dies 200. Various approaches to using white
dies 200 are discussed below.
[0106] FIGS. 4A-4E depict one embodiment of process 300. In this
embodiment, a base 410 is provided (step 310) and LEEs 210 are
placed on or adhered to base 410 (step 320) with contacts 220
adjacent to base 410 (FIG. 4A). Base 410 may also be referred to as
a "mold substrate." In one embodiment, base 410 includes or
consists essentially of an adhesive film or tape. In some
embodiments, base 410 includes or consists essentially of a
material to which has a relatively low adhesion to phosphor 230,
that is, it permits removal of cured phosphor 230 from base 410. In
some embodiments, base 410 is the same as or similar to dicing or
transfer tapes used in the semiconductor industry for singulation
and/or transfer of dies, for example Revalpha from Nitto Denko
Corporation or tapes from Semiconductor Equipment Corporation. In
some embodiments, base 410 includes or consists essentially of a
water-soluble material or adhesive, or may be covered or be
partially covered with a water-soluble material. For example, the
adhesive of base 410 or the liner or both may be water soluble. In
some embodiments, the water-soluble material includes or consists
essentially of a water-soluble tape, for example 3M type 5414. In
some embodiments base 410 includes or consists essentially of a
silicone or a silicone-based material, for example PDMS or GelPak
material from the Gel-Pak Corporation.
[0107] In some embodiments, base 410 includes or consists
essentially of a material with variable adhesive force. In this
embodiment the adhesive force may be changed after formation and
curing of the phosphor, to make it easier to remove the white die
or white die wafer from base 410. (A white die wafer, also referred
to as a composite wafer, is herein defined as a plurality of
semiconductor dies suspended in a binder.) In one embodiment such a
variable adhesive force material may be a thermal release tape or a
UV release tape. In one embodiment the variable adhesive force
material may be a water-soluble tape. In one embodiment the
variable adhesive force material may be an electrostatic chuck
(LEEs 210 are formed or placed on the electrostatic chuck, similar
to the structure shown in FIG. 4A). In this embodiment LEE 210 are
held in place on the electrostatic chuck by electrostatic forces
that may be activated or deactivated electrically.
[0108] In some embodiments, it is desirable for all or a portion of
the face of contact 220 to be exposed after formation of white die
200, that is, to not be covered by phosphor 230. In some
embodiments, placing or adhering all or a portion of the face of
contact 220 adjacent to base 410 prevents coverage or formation of
phosphor 230 over all or a portion of contact 220 or over all or a
portion of the face of contact 220. In some embodiments, the
thickness, hardness and/or other properties of a coating on base
410, or the properties of base 410, for example an adhesive
thickness, chemical composition, surface energy, hardness,
elasticity, etc., may be varied to ensure the desired level of
exposure of contacts 220, for example by proximity to base 410 or
partial or full embedding of contacts 220 into base 410.
[0109] In some embodiments, base 410 includes or consists
essentially of a surface or a mold (e.g., a non-flat surface). In
one embodiment, barriers 450 are formed by a recess in base 410. In
FIG. 4B barriers 450 are shown as perpendicular or substantially
perpendicular to a surface 435; however, this is not a limitation
of the present invention, and in other embodiments barriers 450
form any angle with surface 435. Base 410 may include or consist
essentially of one or more of a variety of materials, for example
glass, PET, PEN, plastic film, tape, adhesive on plastic film,
metal, acrylic, polycarbonate, polymers, silicone,
polytetrafluoroethylene (Teflon), or the like. In some embodiments,
base 410 is rigid or substantially rigid, while in others base 410
is flexible. In some embodiments, it is advantageous for base 410
to include or consist essentially of a "non-stick" material such as
Teflon, or a fluorinated material such as Fluon ETFE produced by
Asahi Glass or to include a non-stick coating over the surface or
portion of the surface that may come in contact with phosphor 230
(for example the binder in phosphor 230) so that phosphor 230 does
not stick to base 410. In some embodiments, base 410 includes or
consists essentially of a layer of material on surface 435 and/or
barriers 450 that does not adhere well to the binder material. In
some embodiments, base 410 includes or consists essentially of a
water-soluble material or adhesive, or base 410 is partially or
completely lined with a water-soluble material to aid in the
release of base 410 from the material formed in base 410. In one
embodiment, base 410 includes or consists essentially of or is
partially or fully lined with a water-soluble tape, for example 3M
type 5414. In some embodiments, base 410 is transparent to light,
for example to visible or UV radiation. In some embodiments, the
height of barrier 450 ranges from about 10 .mu.m to about 1000
.mu.m; however, the height of barrier 450 is not a limitation of
the present invention, and in other embodiments barrier 450 has any
height. In some embodiments, the area of base 410 is in the range
of about 0.25 mm.sup.2 to about 900 cm.sup.2; however, the area of
base 410 is not a limitation of the present invention, and in other
embodiments the area of base 410 is smaller or larger. When barrier
450 is not a part of base 410, barrier 450 may include or consist
essentially of a material similar to that or different from that of
base 410. In some embodiments, barrier 450 may be a ring or stencil
surrounding LEE 210.
[0110] The spacing between adjacent LEEs 210 identified as a
spacing 405 in FIG. 4A may be adjusted to control the width of
phosphor 230 around the sides of LEEs 210. In one embodiment,
spacing 405 between LEEs 210 is approximately determined by the sum
of twice the desired sidewall thickness 250 of the phosphor and the
kerf (where the kerf is the width of the region removed during the
singulation process of white dies 200, for example identified as
kerf 470 in FIG. 4D). In other embodiments, as discussed herein,
the spacing 405 is independent of the amount of phosphor 230
surrounding LEEs 210. The thickness of phosphor 230 over the LEEs
210 may be controlled by controlling a thickness 425 of phosphor
420 that is formed or dispensed. In one embodiment, thickness 260
of phosphor 230 over LEE 210 is given approximately by the
thickness 425 less the thickness 445.
[0111] The next step (step 330) in process 300 provides a phosphor
(uncured or partially cured phosphor 420). In one embodiment,
phosphor 420 includes or consists essentially of a phosphor and a
binder. In some embodiments, the phosphor and binder are mixed
prior to application, for example in a centrifigual mixer, with or
without a partial vacuum over the mixture.
[0112] In the next step (step 340) in process 300, phosphor 420 is
formed over base 410 and LEEs 210 as shown in FIG. 4B. In some
embodiments, phosphor 420 is contained or bounded by surface 435 of
base 410 and optional sides or barriers 450 as shown in FIG. 4B. In
this example phosphor 420 has a bottom surface or face 460 and a
top surface or face 440. In some embodiments surfaces 460 and 440
are substantially parallel to each other. In some embodiments
surfaces 460 and 440 are substantially flat and parallel.
[0113] Phosphor 420 may be formed by a variety of techniques, for
example casting, dispensing, pouring, injecting, injection,
compression, transfer or other forms of molding, Mayer bar or
draw-down bar, doctor blade, etc. The method of formation of
phosphor 420 is not a limitation of the present invention. In some
embodiments, base 410 is positioned such that surface 435 is level,
such that when phosphor 420 is formed on base 410, surface 435,
bottom surface 460 of phosphor 420 and top surface 440 of phosphor
420 are parallel or substantially parallel, forming a thin layer of
phosphor 420 that has a uniform or substantially uniform thickness
across all or most of the area of phosphor 420. In some
embodiments, one or more barriers 450 are used to prevent or
partially prevent the spread of phosphor 420. In some embodiments,
surface 435 and barriers 450 form a mold for phosphor 420. In some
embodiments, barriers 450 are portions of a separate component
placed over base 410 surrounding LEEs 210. In some embodiments,
barriers 450 are not used. Some embodiments of the present
invention utilize a level base 410 and gravity to automatically
produce phosphor layer 420 with a uniform or substantially uniform
thickness. In one embodiment, the thickness uniformity of phosphor
420 is within about .+-.15%, within about .+-.10%, within about
.+-.5% or within about .+-.1% or less. In one embodiment, phosphor
420 has a thickness in the range of about 5 .mu.m to about 2000
.mu.m; however, the thickness of phosphor 420 is not a limitation
of the present invention, and in other embodiments phosphor 420 is
thinner or thicker.
[0114] In one embodiment, the time between mixing phosphor 420
including or consisting essentially of binder and phosphor powder
and forming phosphor 420 over base 410 is relatively short compared
to the time required for settling of the powder in the binder, such
that the phosphor and binder form a uniform and homogeneously
distributed or substantially uniform and homogeneously distributed
combination of phosphor powder in the binder. In one embodiment,
the compositional uniformity of phosphor 420, that is the
distribution of phosphor powder in the binder, is uniform to within
about .+-.15%, within about .+-.10%, within about .+-.5% or within
about .+-.1%. In some embodiments of mixtures of phosphor and
powder, settling starts to occur within about 10 to about 30
minutes, while formation of phosphor 420 in over base 410 occurs
within about 0.25 minute to about 5 minutes. In some embodiments,
the structure shown in FIG. 4B is exposed to a partial vacuum to
degas or remove all or a portion of any dissolved gases in phosphor
420, to reduce or eliminate the number of bubbles in phosphor 420.
In some embodiments, phosphor 420 is exposed to a partial vacuum
before formation on base 410. In some embodiments, phosphor 420 is
formed over base 410 in a partial vacuum. In some embodiments of
the present invention, base 410 is not level, resulting in phosphor
420 having a non-uniform thickness over base 410 and LEE 210, as
discussed herein in more detail.
[0115] Phosphor 420 is then cured, producing cured phosphor 230
(step 350) as shown in FIG. 4C. Curing may include or consist
essentially of heating, exposure to radiation of various sources,
for example visible, UV and/or IR light, or chemical curing (i.e.,
introduction of a chemical agent that promotes cross-linking of the
phosphor binder). In one embodiment, phosphor 420 is cured by UV or
other radiation. In one embodiment, base 410 is held within the
curing equipment prior to or just after step 350 of FIG. 3. In some
embodiments of mixtures of binder and powder, settling starts to
occur within about 10 to about 30 minutes, while curing of phosphor
420 over base 410 occurs within about 0.10 minute to about 5
minutes. In one embodiment, steps 340 and 350 may take less than
about 30 minutes, less than about 10 minutes, less than about 5
minutes or less than about 1 minute. In some embodiments the curing
step 350 includes or consists essentially of multiple sub-curing
steps. For example, a first sub-curing step may be performed to
"freeze" the phosphor particles in the matrix and this may be
followed by a second sub-curing step to fully cure the binder. In
some embodiments both the formation and curing process may occur
within about 0.25 minute to about 7 minutes. In some embodiments
both the formation and curing process may take less than about 4
minutes.
[0116] In step 360 from FIG. 3, white dies 200 are separated or
singulated from the structure shown in FIG. 4C (i.e., a white
wafer, white die wafer, or composite wafer), resulting in the
structure shown in FIG. 4D. While FIG. 4D shows each white die 200
including one LEE 210, this is not a limitation of the present
invention and in other embodiments white die 200 includes more than
one LEE 210. White dies 200 may have a size ranging from about 0.25
mm to about 5 mm; however, the size of white dies 200 is not a
limitation of the present invention. For example, a white die
including a large array of LEEs 210 may have a lateral dimension of
at least 3 mm or at least 7 mm or at least 25 mm. For some white
dies 200, separation may be optional, for example in the case of
large arrays of LEEs 210. Separation of phosphor 230 may be
performed by a variety of techniques, for example laser cutting,
cutting with a knife, die cutting, dicing, saw cutting, water jet
cutting, ablation, or the like. In some embodiments, the kerf may
be below about 200 .mu.m or below about 100 .mu.m or below about 50
.mu.m or even below 25 um. This permits very large arrays of white
dies 200 to be formed in a relatively small area with relatively
high throughput and relatively low cost. The molding process leads
to very uniform phosphor thickness, resulting in uniform optical
characteristics. The ability to form a very large number of white
dies 210 from a relatively small area of phosphor, in a relatively
short time, to avoid or minimize settling of the phosphor powder in
the binder, coupled with the relatively high thickness uniformity,
leads to very large arrays of white dies 210 having relatively
narrow distribution of optical characteristics, such as
chromaticity, color temperature, color rendering index (CRI),
luminous flux, etc. and very low manufacture cost. In one
embodiment, an entire wafer of LEE 210 may be batch processed
simultaneously using this approach. For example LEE 210 may be
produced on a 2'' or 4'' or 6'' diameter wafer. After LEEs 210 are
fabricated and singulated (here singulation refers to singulation
of the substrate on which LEE 210 are formed), they may be
transferred to mold substrate 410 for the white die process
detailed herein. In some embodiments the entire wafer amount of LEE
210 may be transferred in batch mode (i.e., together) to mold
substrate 410. In other embodiments LEE 210 may be transferred to
mold substrate 410 die-by-die or in groups of dies.
[0117] In some embodiments, separation (i.e., of the white dies)
takes place before removal from base 410 while in other embodiments
base 410 is removed before separation, as discussed in more detail
herein. In some embodiments, phosphor 230 includes or consists
essentially of only a transparent binder that is transparent to a
wavelength of light emitted by LEE 210.
[0118] In some embodiments, the structure shown in FIG. 4D may be
transferred to another substrate 411 such that contacts 220 are
accessible, as shown in FIG. 4E. Such a transfer may be performed
using transfer tape, a pick-and-place tool with a die flipper or
any other technique. In some embodiments this transfer may be done
in batch mode, while in other embodiments it may be done die-by-die
or in groups of dies. In some embodiments the transfer may be
performed before singulation of the white die wafer. The result of
this process is a white die 200, as shown in FIGS. 2A and 2B. The
process provides a batch method to produce dies integrated with
phosphor, with uniform phosphor over each die, in a cost-effective
way, before the dies are placed or integrated into any kind of
package or onto a circuit board.
[0119] White dies 200 may then be removed from base 410 for
placement in a package. In some embodiments, white dies 200 may be
used as is, without a package, for example by mounting on a
flexible or rigid circuit or wiring board or in other lighting of
illumination systems. White dies 200 may be placed in different
orientations, for example those shown in FIG. 4D or FIG. 4E.
[0120] In one embodiment, only one phosphor 420 is used; however,
this is not a limitation of the present invention, and in other
embodiments a plurality of phosphors are used. In one embodiment,
phosphor 420 may include or consist essentially of a plurality of
different phosphor powders. In one embodiment, a first phosphor 420
is deposited and cured or partially cured, followed by the
deposition and curing of one or more successive phosphors. In one
embodiment, a binder is deposited and cured or partially cured, and
the binder is transparent to a wavelength of light emitted by LEE
210 and/or phosphor 420 or 230, followed by the deposition and
curing of one or more phosphor 420, to form a layered structure in
which one or more layers have a phosphor composition, type and/or
thickness different from each other. In this way, a remote-phosphor
white die 400 may be fabricated, as shown in FIG. 5. FIG. 5 shows
one embodiment of a remote phosphor white die 500, in which
phosphor 230 is spatially separated from LEE 210 by a transparent
binder or matrix material 510. In such a structure the extent of
the overhang of the phosphor containing layer(s) 230 past the edges
of LEE 210 may be varied to optimize the amount of light from LEE
210 that is absorbed by phosphor 230. Such an approach may also be
used to form multiple layers of phosphor and/or transparent binder
of LEE 210.
[0121] The following examples present some embodiments of the
present invention. However these are not limiting to the method of
manufacture or structure of the white die.
Example 1
[0122] In this example LEEs 210 are fabricated in wafer form (i.e.,
as portions of a semiconductor wafer). A wafer may include about
5000 or more LEEs 210. In some embodiments, a wafer includes over
about 20,000, over 100,000, or over 500,000 LEEs 210. After
fabrication of LEEs 210, LEEs 210 are tested and sorted into bins,
as shown in steps 610, 620 of FIG. 6. Bins may include, for example
emission wavelength, forward voltage, light output power or the
like. The particular choice of one or more bins or range of values
within the one or more bins is not a limitation of the present
invention. In one embodiment, LEEs 210 are binned by emission
wavelength. The process shown in FIG. 3 may then carried out on
each bin of LEEs 210. The composition and amount of phosphor
applied over base 410 and LEE 210 is determined in advance to
achieve the desired color point, chromaticity, color temperature,
CRI or other optical properties, based on the emission wavelength
of each bin. In this embodiment, each bin may have a different
composition and/or thickness of phosphor to achieve the desired
optical properties. In one embodiment, the phosphor composition and
thickness are adjusted based on the bin information to achieve a
relatively more narrow distribution in optical properties (for
example color temperature) than would be achievable without
binning.
[0123] For example, in FIG. 7, wafer 710 represents a wafer
containing the total distribution of characteristics from
fabricated LEEs 210 from a wafer or growth run or series of growth
runs as well as one or more process runs. During the growth or
deposition process for the epitaxial structure, and subsequent
fabrication steps to form LEEs 210, variation in optical and
electrical properties may be introduced. LEEs 210 are tested and
sorted into bins, where each bin has a relatively narrow
distribution of one or more characteristics. For example,
wavelength bins may have about 5 nm or about 2.5 nm distributions.
Other examples of bins include forward voltage and light output
power. Bins 720, 730 and 740 represent different bins, for example
three different wavelength bins. In FIG. 7, the boxes representing
bins 720, 730 and 740 have a small graph representing the
distribution of dies with a particular characteristic in that bin.
While three bins are shown in FIG. 7, this is not a limitation of
the present invention, and in other embodiments fewer or more than
three bins are utilized. LEEs 210 from each bin, designated 210',
210'' and 210' are used to determine the characteristics of
phosphor 230 (i.e., to achieve a final optical characteristic of
the LEE and phosphor combination), resulting in a corresponding
number of different phosphor mixes, identified as 230', 230'' and
230'. This results in a corresponding number of bins of white die
200, designated 200', 200'' and 200'. In this way a relatively
larger percentage of the distribution of LEEs 210 from the entire
manufacturing process may be fabricated into white dies 200 having
a relatively narrow distribution of optical characteristics, for
example color temperature.
[0124] A flow chart of this process is shown in FIG. 6. The LEEs
210 are first tested (step 610) and then sorted and separated into
bins (step 620). One bin of LEEs 210 is chosen (step 630) and a
phosphor is prepared to achieve the desired optical properties for
that particular bin of LEEs 210 (step 640). This phosphor may
include or consist essentially of one or more phosphor powders or
light-conversion materials. Finally, in step 650, process 300 shown
in FIG. 3 is carried out using the selected bin of LEEs 210 and
phosphor prepared for that bin of LEEs 210. This may be repeated
for the other bins.
Example 2
[0125] In this example LEEs 210 are fabricated in wafer form. A
wafer may include over about 5000 or more LEEs 210. In some
embodiments, a wafer may include over about 20,000 or over 100,000
LEEs 210. After fabrication of LEEs 210, LEEs 210 are tested, or
some of LEEs 210 on each wafer are tested. In one embodiment, the
process shown in FIG. 3 is then carried out on all LEEs 210 from
the wafer. The composition and amount of phosphor applied over base
410 and LEE 210 is determined in advance to achieve the desired
color point, color temperature, CRI or other optical properties,
based on the test results of LEE 210 on that wafer. This phosphor
may include or consist essentially of one or more phosphor powders
or light-conversion materials.
[0126] In one embodiment of this example, there is no testing done
on LEEs 210 prior to formation of the phosphor over LEEs 210. In
one embodiment of this example, the starting wafer is applied to
dicing tape, after which the wafer is singulated into LEEs 210. The
tape has the ability to expand and is expanded to provide the
required spacing between LEE 210 to achieve the desired size
phosphor over LEEs 210. In one embodiment the spacing between LEEs
210 is approximately given by the sum of twice the sidewall
thickness of the phosphor (thickness of the phosphor on the side of
LEE 210) and the kerf. An example of such an expansion tape is
SWT20+ manufactured by Nitto Denko.
[0127] If the singulation is performed with the contacts down on
the tape, the tape may be used as base 410. If the singulation is
performed with the contacts up (not adjacent to the tape), LEEs 210
may be transferred using transfer tape or other transfer methods.
In the tape-transfer operation a second substrate or tape is
applied to the exposed side (here contact side) of LEEs 210 and the
first tape is removed. A variety of techniques may be used for such
transfer, for example using tapes of different tack levels, thermal
release tape and/or UV release tape. An advantage of this approach
is that LEEs 210 are then positioned correctly on base 410 without
any need for a serial pick-and-place process, saving time and
money. In another embodiment, LEEs 210 may be placed on base 410 at
the correct spacing, using semi-batch or serial techniques, for
example pick-and-place. FIGS. 8A-8D depict a schematic of one
embodiment of this process. In FIG. 8A, tape 820 is applied to the
back of wafer 810 (in this example the contacts are face up). FIG.
8B shows the structure of FIG. 8A at a later stage of manufacture.
In FIG. 8B wafer 810 has been singulated, resulting in LEEs 210 on
tape 820. The spacing 830 between LEE 210 is determined by the
singulation process. In some embodiments, spacing 830 is in the
range of about 15 .mu.m to about 100 .mu.m. FIG. 8C shows the
structure of FIG. 8B at a later stage of manufacture. In FIG. 8C,
tape 820 has been optionally expanded or stretched. Space 830,
identified as space 830' after expansion, is set to the correct
value for making white dies, as described above, by the expansion
process. That is, tape 820 is expanded until the spacing between
adjacent LEEs 210 is appropriate to make white dies 200 having a
desired thickness of phosphor thereon. FIG. 8D shows the structure
of FIG. 8C at a later stage of manufacture. In FIG. 8D a second
tape 840 is applied to the contact side of LEE 210. Finally, first
tape 820 is removed, leaving the structure shown in FIG. 4A,
whereupon the process described above in FIG. 3 and shown in FIGS.
4A-4D may be carried out. In some embodiments, tape 840 is the base
or mold substrate 410 shown in FIG. 4A.
Example 3
[0128] In this embodiment, the process starts with the structure
shown in FIG. 4C or FIG. 4D. In some embodiments of this example,
LEEs 210 have been binned, while in other embodiments LEEs 210 have
not been binned or may have not been tested. In some embodiments of
this example some of LEEs 210 have been tested. The process by
which the structure shown in FIG. 4C is formed is not a limitation
of the present invention. The structure shown in FIG. 4C may be
called a white wafer or a white die wafer, featuring a plurality of
LEEs 210 and phosphors 230 before singulation. The structure in
FIG. 4D includes a plurality of white dies 200 on mold substrate
410.
[0129] White dies 200 are tested either in white wafer form (shown,
for example, in FIG. 4C) or in singulated form (shown, for example,
in FIG. 4D). Testing may be performed by applying a current and
voltage to contacts 220 and measuring the emitted light. In one
embodiment, contacts 220 are accessed for testing by probes or
needles that poke or penetrate through tape 410. In other
embodiments, testing is performed by first transferring the
structure in FIG. 4C or white dies 200 in FIG. 4D to another
carrier such that contacts 220 are face up and directly accessible.
Such a transfer may be performed in a batch process, similar to
that using transfer tape described in conjunction with FIGS. 8A-8D,
or may be performed in a semi-batch process or a serial process,
such as pick-and-place. Once the structure from FIG. 4C or white
dies 200 are oriented with the contacts accessible, they may be
tested using conventional test equipment, for example manual,
semi-automatic or fully automatic test equipment that applies a
current and voltage to LEEs 210, and measuring the light properties
of white dies 200. In one embodiment, the white wafer of FIG. 4C or
white die 200 of FIG. 4D may be processed in wafer form, similar to
what is done with conventional semiconductor wafers. In this case
the structures in FIGS. 4C and 4D may be sufficiently rigid, or an
additional backing material or plate or carrier may be used provide
additional rigidity so that the white wafer may be handled and
tested in a fashion and using equipment similar to that used for
semiconductor wafers.
[0130] In one embodiment, after testing, white dies 200 are
physically sorted and binned. This results in multiple bins having
different optical properties that may then be used for different
products. In one embodiment, the bins correspond to different
values of color temperature.
[0131] In one embodiment, after testing, white dies 200 are
virtually sorted and binned. In accordance with preferred
embodiments, virtual sorting and binning means that a map of the
characteristics of each white die 200 is produced, and white dies
200 are put into, or assigned, to virtual bins based on their
optical and/or electrical properties, for example color temperature
or forward voltage. When using these virtually binned white dies
200 for products that require different characteristics, the bin
map is used to select white dies 200 from the appropriate one or
more bins for that particular product. The remaining white dies 200
from other bins may then be used in a different product at a
different time.
[0132] In one embodiment, white dies 200 are used without testing
or binning.
[0133] In any approach, if the starting point of the process is the
structure shown in FIG. 4C, the structure may be singulated to form
white dies 200 before or after testing. Furthermore, before either
physical or virtual white die 200 binning, the white wafers (FIG.
4C or 4D) may also be binned, either physically or virtually.
Example 4
[0134] In one embodiment the body of LEE 210 stands above base or
tape 410, as shown in FIG. 9A. After formation of the phosphor, the
white die structure may include a portion of the phosphor around
and covering all or a portion of the edges of the white die, as
shown in FIG. 9B. An enlarged view of such a white die is shown in
FIG. 9C. In some embodiments, base 410 is deformable or flexible
such that portions of one or more contacts 220 are embedded into
tape 410, as shown for structure 910. Structure 910 has coplanar
contacts, but this is not a limitation of the present invention,
and in other embodiments LEE 210 has non-coplanar contacts, as
shown in structures 920 and 930. In some embodiments LEEs 210 may
be tilted, as shown for structure 930 in FIG. 9A, resulting in a
similar structure shown in FIG. 9C, but without the need for one or
more contacts 220 to be partially or substantially embedded into
base or tape 410.
[0135] Such a structure may result in enhanced yield. The reason
for this is that the die-singulation process, i.e., where the
semiconductor wafer is separated into individual dies, may result
in chipping or other damage to the passivation at the edge of the
dies. If the chipping or damage to the passivation at the edge
permits exposure of underlying conductive semiconductor material,
undesirable electrical coupling to this conductive semiconductor
material may occur in the attachment process of a white die 210,
resulting in poor device performance and/or shorting of the
device.
[0136] In some embodiments a portion of the body of LEE 210 is not
covered with phosphor, as shown in FIG. 9D. FIG. 9D shows a white
die 200, similar to that shown in FIG. 2A, but with a portion of
the sidewall of the body of LEE 210 not covered in phosphor. The
extent that LEE 210 extends beyond the edge of phosphor 230 may be
identified as the die relief 950. In some embodiments the die
relief is positive, as shown in FIG. 9D, but in other embodiments
the die relief may be substantially zero, as shown in FIG. 2A or
even negative, as shown in FIG. 9E. Another dimension that may be
advantageously controlled is the contact relief 960. The contact
relief 960 is the amount that the contact protrudes from the
adjacent surface of the phosphor. In some embodiments the die
relief may be substantially zero and the contact relief is
positive. In some embodiments both the die and contact relief are
positive. The polarities and absolute values for the die and
contact relief are not a limitation of the present invention. In
some embodiments the contact relief is positive and in the range of
about 1 .mu.m to about 15 .mu.m.
[0137] In some embodiments it is advantageous to control the die
and/or contact relief, for example in some embodiments the
variation in die and/or contact relief is less than about 30%, or
less than about 15% or less than about 10%. Die and/or contact
relief may be controlled by a number of different techniques. In
some embodiments LEEs 210 are partially embedded in mold substrate
410, as shown in FIG. 9F. The amount of relief 970 (here relief may
refer to either die or contact relief or the combination) is then
substantially determined by the size of dimension 970 that LEE 210
is embedded in mold substrate 410, as shown in FIG. 9F.
Example 5
[0138] FIGS. 10A-10C depict another technique for fabricating white
dies 200 in accordance with various embodiments of the present
invention. In such embodiments LEEs 210 are attached to a mold
substrate or temporary carrier 410 with the contacts adjacent to
temporary carrier 410. A mold 1030 includes or consists essentially
of one or more compartments, depressions, or wells 1020 into which
LEEs 210 will be inserted or partially inserted or over or under
which LEEs 210 will be suspended (for example, if barriers
separating the compartments do not extend sufficiently far to form
fully closed compartments). In another embodiment wells 1020 are
formed by insertion of a template into an open mold (such as that
shown in FIG. 4B). Wells 1020 are filled or partially filled with
phosphor 420, for example by dispensing, by the doctor blade
method, stencil printing, or by other means. Following formation of
phosphor 420 in wells 1020, temporary carrier or base 410 is mated
with mold 1030 such that LEEs 210 are fully or partially immersed
in phosphor 420, as shown in FIG. 10B. Contacts 220 are adhered to
temporary carrier 410, preventing phosphor 420 from covering at
least a portion of contacts 220. In one embodiment phosphor 420 is
introduced or injected into wells 1020 after mold 1030 is mated
with base 410. In one aspect of this embodiment, a partial vacuum
may be used to enhance transport of phosphor 420 to all wells 1020
and to partially or fully degas phosphor 420 before curing. The
process may include or consist essentially of injection molding,
transfer molding, compression molding, casing etc. Compression
molding may be carried out using equipment such as a FFT-103
manufactured by Towa Corporation. In some embodiments, mold 1030 is
flat, i.e., effectively including only one depression 420 into
which fits multiple LEEs 210. In one embodiment, the structure of
FIG. 10B is flipped, with base 410 on the bottom and mold 1030 on
top, such that phosphor 420 is formed over base 410 and LEE 210,
over which a top portion 1031 of the mold 1030 is formed and in one
embodiment of this example mold 1030 is a flat surface. For
example, the structure of FIG. 4B may be filled or over-filled with
phosphor 420, after which a mold top or cover 1031 is applied, as
shown in FIG. 10D. The shape of mold 1030 is not a limitation of
the present invention and in other embodiments mold 1030 has any
shape. In some embodiments, both base 410 and mold 1030 have raised
barriers or sidewalls. As discussed herein, a pattern, roughness or
texture in all or a portion of the outer surface of phosphor 230
may be formed by introducing those features into the surface of all
or portions of the surface of the mold. In some embodiments,
different LEEs 210 on base 410 have differently shaped phosphors
formed around them.
[0139] In some embodiments all or a portion of mold 1030 is covered
by a mold release material. In some embodiments the mold release
material is a mold release film. In some embodiments the mold
release material or mold release film may be patterned, roughened
or textured to, e.g., impart similar features on all or portions of
the outer surface of phosphor 230. In some embodiments the mold
release material or mold release film may be smooth or
substantially smooth.
[0140] After curing of phosphor 420 and removal from mold 1030, the
structure is as shown in FIG. 10C. FIG. 10C shows white dies 200
with phosphor 230 covering the sides and bottom of LEEs 210, with
contacts 220 of LEEs 210 adhered to temporary carrier 410 and not
covered with phosphor 230. In one embodiment, temporary carrier 410
includes or consists essentially of tape or film, as discussed
above, from which white dies 200 may be picked for placement in a
lighting or other system. The width 250 of phosphor 230 (FIG. 2A)
around the edges or sides of LEEs 210 may be controlled by
controlling the width 1040 of depression 1020 relative to the size
of LEE 210. In one embodiment, the thickness of phosphor 230 on the
sides of LEE 210 is approximately given by one-half of the
difference between width 1040 and the width 1060 of LEE 210. (The
width 1060 of LEE 210 may not be constant in all dimensions.) In
one embodiment the thickness 260 of phosphor 230 (FIG. 2A) over LEE
210 may be controlled by controlling the depth 1050 of depression
1020 relative to the thickness of LEE 210. In one embodiment the
thickness 260 of phosphor 230 (FIG. 2A) over LEE 210 may be
controlled by various operational parameters of the molding
process, for example the amount of phosphor present during
compression molding. In some embodiments the thickness 260 of
phosphor 230 (FIG. 2A) over LEE 210 is controlled by more than one
factor. In one embodiment, thickness 260 is approximately the depth
1050 of well 1020 less the height 445 of LEE 210 above base 410
(FIG. 4B). In some embodiments where a plurality of LEEs 210 are
formed in each depression, or where mold 1030 has only one
depression, white die 200 may include a plurality of LEEs 210 or
white die 200 may be formed by singulation of phosphor 230. In
other words, the structure shown in FIG. 4C may also be produced by
a molding process.
[0141] In some embodiments, excess phosphor 420 may be squeezed out
into the region outside of the mold, for example outside of
depression 1020, between base 410 and mold 1030. In one embodiment
of this example, one or more portions of the mold have one or more
openings or through-holes 1100 that provide an overflow pathway for
phosphor 420 during the mating process, as shown in FIG. 11.
Phosphor 420 is formed in wells 1020 as discussed above. When base
410 and mold 1030 are mated, hole 1100 provides a pathway for
excess phosphor 420 to escape, thereby permitting the manufacture
of white die 210 with wells 1020 completely or substantially full
of phosphor, without excess phosphor squeezing out the sides of the
mold. In some embodiments, this provides improved control of the
thickness of phosphor 230 as well as a more reproducible
manufacturing process. This approach may be applied to other
embodiments, for example that shown in FIG. 10D, or in
configurations where phosphor 420 is formed in the mold after
mating of base 410 and mold 1030. As discussed previously, control
of phosphor thickness 260 and 270 may be very important to
maintaining uniform optical characteristics. In the arrangement
discussed here the phosphor thickness may be controlled by the
dimensions of well 1020, which is independent of the process
parameters for dispensing or forming phosphor 420 in well 1020. In
this embodiment a small excess of phosphor 420 is formed in well
1020, and when base 410 is brought into contact with mold 1030,
excess phosphor 420 may move into hole 1100. After mating of tape
410 and mold 1030, phosphor 420 may be cured to form, and the
amount of phosphor over LEE 210 is controlled by the geometry of
the structure, rather than by the formation or dispense parameters.
In one embodiment, base 410 and mold 1130 are held together by
vacuum or pressure during all or a portion of the cure operation.
In some embodiments phosphor 420 is injected into the mold through
holes 1100.
[0142] While FIG. 10C shows white dies 200 as completely separated
after the mold process, without any additional singulation process,
this is not a limitation of the present invention and in other
embodiments white dies 200 may be connected together by a thin web
of phosphor 230 as a result of the mold process as discussed herein
in reference to FIG. 12F. In some embodiments the web may have a
thickness in the range of about 5 .mu.m to about 100 .mu.m. In some
embodiments white dies 220 may be shaped, as discussed below, but
connected after molding, and require a subsequent singulation
process.
Example 6
[0143] Example 6 is very similar to Example 5, with the difference
that well 1020 in mold 1030 may be modified to have any arbitrary
shape. Such shaping may be done, for example, to improve light
extraction. FIGS. 12A-12D depict several embodiments of white dies
200 that may be fabricated with a shaped mold. The structure of
FIG. 12A has a reduced amount of phosphor over the corners of LEE
210 than over the center of LEE 210. The structure of FIG. 12B has
a non-smooth, for example textured, rough, or patterned, surface
1210. In one embodiment, the non-smooth surface 1210 reduces total
internal reflection (TIR) within phosphor 230 and achieves improved
light extraction. In one embodiment surface 1210 may have a
periodic structure; however, this is not a limitation of the
present invention, and in other embodiments the structure may be
random. In one embodiment surface 1210 may include light extraction
features (e.g., raised bumps and/or depressions) having a dimension
in the range of about 0.5 .mu.m to about 5 .mu.m; however, this is
not a limitation of the present invention, and in other embodiments
the light extraction features may have other dimensions. In one
embodiment the light extraction features may be hemispherical or
pyramidal in shape; however, this is not a limitation of the
present invention, and in other embodiments the light extraction
features may have any shape. In one embodiment the light extraction
feature is a random texture or roughness with an average roughness
in the range of about 0.5 .mu.m to about 10 .mu.m. In the structure
of FIG. 12C, the phosphor is shaped in a lens shape. Such a lens
may be a hemisphere, a paraboloid, a Fresnel optic or any other
shape. The structure of FIG. 12D has a photonic crystal 1220 formed
on the top surface. In one embodiment, the photonic crystal 1220
increases the intensity of light exiting white die 200 in a
specific direction, for example perpendicular to the face of white
die 200. In other embodiments, a photonic crystal is formed on all
or a portion of any surface of white die 200. FIG. 12E shows a
portion of a white wafer having contiguous molded shapes over LEEs
210. In some embodiments this is singulated, for example at the
joining line 1230 to form individual white dies 210, while in other
embodiments a white die 210 may include a plurality of LEEs 210
with a plurality of shaped phosphors 230, as shown in FIG. 12F. As
shown in FIG. 12F, the shaped phosphors 230 may be connected by a
thin region 1250. In some embodiments region 1250 may be
advantageously minimized to reduce the consumption of unused
phosphor, for example by minimizing the thickness and/or lateral
extent of region 1250. However, this is not a limitation of the
present invention, and in other embodiments region 1250 may have
any shape or size or may be absent, as described herein.
[0144] In one embodiment the phosphor may be shaped by forming a
white die as shown in FIG. 2A or a white die wafer as shown in FIG.
4C and then removing one or more portions of the phosphor to
produce a shape different from the starting shape. Removal of one
or more portions of the phosphor may be accomplished using a
variety of means, for example knife cutting, dicing, laser cutting,
die cutting, or the like.
Example 7
[0145] In this embodiment of the present invention, the process
starts with providing base 410, as described above. In one
embodiment, base 410 includes or consists essentially of a film or
tape. In one embodiment, base 410 includes or consists essentially
of an adhesive tape, for example an adhesive tape where the
adhesive is, for example a thermal release adhesive, a UV release
adhesive, a water-soluble adhesive or the like. LEEs 210 are then
formed or placed on or over base 410, as shown in FIG. 13A. In this
example, LEEs 210 are placed such that contacts 220 are face up,
i.e., not adjacent to base 410, in contrast to previous examples in
which contacts 220 were placed on base 410.
[0146] FIG. 13B shows the structure of FIG. 13A at a later stage of
manufacture. After placing LEEs 210 on base 410, phosphor 420 is
provided, as described above, and formed over LEEs 210 and base
410. As shown in FIG. 13B, the phosphor level is coplanar, or
substantially coplanar with surface 1310 of LEE 210, leaving
contacts 220 exposed. In other embodiments, the phosphor level may
be controlled to achieve a desired contact and/or die relief.
Phosphor 420 may be formed by a variety of techniques, for example
dispensing, pouring, injecting, molding, etc. The method of
formation of phosphor 420 over LEEs 210 and base 410 is not a
limitation of the present invention. In some embodiments, base 410
is positioned such that a surface 1310 of the LEE 210 is level,
such that when phosphor 420 is formed over base 410, surface 1310
and surface 460 are parallel or substantially parallel, forming a
thin layer of phosphor 420 that has a uniform or substantially
uniform thickness across all or most of the area of phosphor 420.
In some embodiments, formation of phosphor 420 is accomplished
using a Mayer bar or draw-down bar, to achieve a uniform layer of
phosphor 420. However it is formed, in one aspect of the present
invention a level mold and gravity are used to automatically
produce phosphor layer 420 with a uniform or substantially uniform
thickness. In other aspects of this invention, the uniform or
substantially uniform thickness is achieved through a molding
process, as discussed above. In one embodiment, the thickness
uniformity of phosphor 420 is within about .+-.15%, within about
.+-.10%, within about .+-.5% or within about .+-.1%. In one
embodiment, phosphor 420 has a thickness in the range of about 1
.mu.m to about 2000 .mu.m; however, the thickness of phosphor 420
is not a limitation of the present invention, and in other
embodiments phosphor 420 is thinner or thicker.
[0147] As shown in FIG. 13B, in one embodiment a surface 1320 of
phosphor 420 is coplanar or substantially coplanar with surface
1310 of LEEs 210. In this example phosphor 420 covers all or
substantially all of the sidewalls of LEE 210. In one embodiment,
phosphor 420 is formed on base 410 to such a level. In another
embodiment, phosphor 420 is formed over top surface 1310 of LEE 210
and a portion of phosphor 420 (or phosphor 230 after curing) is
subsequently removed to provide electrical access to contacts 220.
In another embodiment, phosphor 420 is formed below top surface
1310 of LEE 210, for example to achieve positive die relief. In one
embodiment the amount of die relief may be controlled by varying
the level of phosphor 420 relative to top surface 1310 of LEE
210.
[0148] Phosphor 420 is then cured or partially cured, where cured
phosphor is identified as cured phosphor 230. Curing may include or
consist essentially of heating, exposure to radiation of various
sources, for example visible, UV and/or IR light, or chemical
curing, as discussed previously. In one embodiment, phosphor 420 is
cured by UV or other radiation and base 410 is transparent to such
radiation.
[0149] In one embodiment, phosphor 420 includes or consists
essentially of a light-cured binder. In this embodiment, phosphor
420 is initially formed to a height above that of LEE 210, as shown
in FIG. 13C. Exposure of phosphor 420 to light (exposure radiation)
through the back side of LEE 210, which is transparent or partially
transparent to such light, (that is the side opposite that to which
LEE 210 are attached) will cure phosphor 420 except for portions
over contacts 220, where contacts 220 are opaque or substantially
opaque to such exposure radiation, as shown in FIG. 13D. The
uncured phosphor 420 may then be removed, providing access to
contacts 220 for electrical coupling, as shown in FIG. 13E. Cured
phosphor 230 then covers all of LEE 210 except for opaque or
substantially opaque contacts 220. If the surface of LEE 210
outside of contacts 220 is covered or partially covered with a
material opaque or partially opaque to the exposure radiation, for
example with a minor or other reflective material, then phosphor
420 that was situated above the opaque or partially opaque region
will not be exposed to light and will also be removed.
[0150] The structures shown in FIG. 13B or 13E may be used at this
point or singulated and used at this point in the process. However,
these structures typically do not have the face opposite the
contact face covered with phosphor. This may result in undesirably
high blue emission in the spectra and/or loss of total emitted
light and thus a reduction in efficiency. Several methods may be
used to form white dies that are more completely encased in
phosphor. In a preferred embodiment, the structures shown in FIG.
13B or 13E are transferred to second base 1330, for example using
transfer methods described previously, such that contacts 220 are
adjacent to second base 1330, as shown in FIG. 13F.
[0151] In some embodiments, second base 1330 is similar to or the
same as base 410. After this transfer process, one or more
additional layers of phosphor 420' may be formed over the structure
shown in FIG. 13F, as shown in FIG. 13G. Phosphor 420 is then cured
and the dies may be separated, as discussed above, resulting in the
white die 1410, as shown in FIG. 14A. White die 1410 is similar to
white die 200 shown in FIG. 2A, with the difference that the
encasing phosphor is formed in at least two steps for white die
1410, while only one step may be required for phosphor formation of
white die 200. FIG. 14A shows an example of a white die 1410 in
which both portions of phosphor 230 (cured phosphor) are the same
while FIG. 14B shows an example of a white die 1410' in which
phosphor 230 is different from phosphor 230'. White die 1410 and
1410' in FIGS. 14A and 14B show two portions of phosphor 230 (or
230'); however, this is not a limitation of the present invention,
and in other embodiments phosphor 430 may be composed of more than
two portions or layers.
[0152] FIG. 14C shows a structure similar to those shown in FIGS.
14A and 14B, but in this case a surface 1320 of phosphor 230 is
above the bottom surface of LEE 210 to generate a positive contact
relief 960.
Example 8
[0153] In this example, white die 1510 includes multiple conformal,
substantially conformal or semi-conformal phosphor coatings, as
shown in FIG. 15E. The process to make white dies 1510 starts with
the structure shown in FIG. 15A, featuring base 410 and LEEs 210
mounted over base 410 with contacts 220 adjacent to base 410. A
stencil, mold, template, barrier or other structure, identified as
barrier 1520 in FIG. 15B, is then formed over base 410 in between
LEEs 210. Phosphor 420 is then formed in the regions between
barriers 1520, as shown in FIG. 15B. Phosphor 420 is then cured or
partially cured and barrier 1520 removed (after partial or full
curing of phosphor 420) leaving the structure shown in FIG. 15C.
Each of the structures in FIG. 15C is basically white die 210, but
manufactured in a different process than described above. In
another embodiment, the structure of FIG. 15C is formed in other
ways, for example by starting with a structure similar to that
shown in FIG. 4C and removing a portion of phosphor 230 between
LEEs 210. Removal of phosphor 230 may be done by a variety of
techniques, for example cutting, laser ablation, laser cutting,
etching, sandblasting or the like. The method of removal of
phosphor 230 is not a limitation of the present invention.
[0154] FIG. 15D shows the structure of FIG. 15C at an optional
later stage of manufacture. In FIG. 15D, phosphor 230' has been
formed over the structure of FIG. 15C. In some embodiments phosphor
230' is the same as phosphor 420 or phosphor 220, while in other
embodiments phosphor 230' is different from phosphor 420 or
phosphor 220. Phosphor 230' is then cured or partially cured,
forming cured phosphor 230' and resulting in the structure of FIG.
15D. FIG. 15E shows the structure of FIG. 15D at a later stage of
manufacture in which white dies 1510 are formed by separation of
phosphor 230'. FIG. 15E shows two layers or levels of phosphor, 230
and 230'; however, this is not a limitation of the present
invention, and in other embodiment, more than two layers or levels
of phosphor are utilized. In some embodiments, the layer of
phosphor closest to LEE 210 includes or consists essentially of a
transparent binder and no phosphor. FIG. 15E shows each layer or
level of phosphor having substantially the same conformal shape
around LEE 210; however, this is not a limitation of the present
invention, and in other embodiments the shape of each phosphor
layer or level is different, for example as shown in FIGS. 12A-12D.
In some embodiments, different layers of phosphor serve different
purposes, for example to improve light extraction from LEE 210
and/or phosphor 230 or to convert light from LEE 210 to a different
wavelength.
[0155] While FIGS. 15A-15E show an example of multiple phosphor
coatings having a rectangular solid volume, this is not a
limitation of the present invention, and in other embodiments
multiple shaped coatings may be formed, as shown in FIG. 15F. While
FIGS. 15A-15E show an example of multiple conformal phosphor
coatings (i.e., each coating having the shape of the previous one
thereunder), this is not a limitation of the present invention, and
in other embodiments the various coatings are not conformal, as
shown in FIG. 15G.
Example 9
[0156] This example uses a process similar to that discussed with
reference to FIG. 4D. However, in this example, instead of one LEE
210 per white die 200, this embodiment features a plurality of LEEs
210 in each white die 200. FIGS. 16A-16C show several examples of
white dies 1610 each featuring a plurality of LEEs 210. FIG. 16A
shows a cross-sectional view of a multi-LEE white die comprising
five LEEs 210. FIG. 16B shows a plan view of a multi-LEE white die
comprising nine LEEs 210 in a 3.times.3 array. FIG. 16C shows a
plan view of a multi-LEE white die comprising four LEEs 210 in a
1.times.4 array. The examples in FIG. 16A-16C show rectangular
white dies; however, this is not a limitation of the present
invention, and in other embodiments the white die are square,
triangular, hexagonal, round or any other shape. The examples in
FIG. 16A-16C show LEEs 210 in a regular periodic array; however,
this is not a limitation of the present invention, and in other
embodiments LEEs 210 are arrayed or spaced in any fashion.
Example 10
[0157] FIGS. 17A and 17B depict an exemplary LEE 1700 for use in an
embodiment of the present invention. FIG. 17A shows a
cross-sectional view while FIG. 17B shows a top plan view of LEE
1700. LEE 1700 typically includes a substrate 1710 with one or more
semiconductor layers disposed thereover. In this exemplary
embodiments, LEE 1700 represents a light-emitting device such as a
LED or a laser, but other embodiments of the invention feature one
or more semiconductor dies with different or additional
functionality, e.g., processors, sensors, photovoltaic solar cells,
detectors, and the like. Non-LED dies may or may not be bonded as
described herein, and may have contact geometries differing from
those of LEDs. While FIGS. 17A and 17B show LEE 1700 having
non-coplanar contacts 1760 and 1770, this is not a limitation of
the present invention and in other embodiments LEE 1700 may have
coplanar or substantially coplanar contacts, as shown in FIG. 17C
(in FIG. 17C the internal structure for contacting the various
layers is not shown for clarity).
[0158] Substrate 1710 may include or consist essentially of one or
more semiconductor materials, e.g., silicon, GaAs, InP, GaN, and
may be doped or substantially undoped (e.g., not intentionally
doped). In some embodiments, substrate 1710 includes or consists
essentially of sapphire or silicon carbide. Substrate 1710 may be
substantially transparent to a wavelength of light emitted by the
LEE 1700. As shown for a light-emitting device, LEE 1700 may
include first and second doped layers 1720, 1740, which preferably
are doped with opposite polarities (i.e., one n-type doped and the
other p-type doped). One or more light-emitting layers 1730, e.g.,
one or more quantum wells, may be disposed between layers 1720,
1740. Each of layers 1720, 1730, 1740 may include or consist
essentially of one or more semiconductor materials, e.g., silicon,
InAs, AlAs, GaAs, InP, AlP, GaP, InSb, GaSb, AlSb, GaN, AlN, InN,
and/or mixtures and alloys (e.g., ternary or quaternary, etc.
alloys) thereof. In preferred embodiments, LEE 1700 is an
inorganic, rather than a polymeric or organic, device. In some
embodiments, substantially all or a portion of substrate 1710 is
removed prior to formation of the phosphor, as described below.
Such removal may be performed by, e.g., chemical etching, laser
lift-off, exfoliation, mechanical grinding and/or
chemical-mechanical polishing or the like. In some embodiments all
or a portion of substrate 1710 may be removed and a second
substrate--e.g., one that is transparent to or reflective of a
wavelength of light emitted by LEE 1700--is attached to substrate
1710 or semiconductor layer 1720 prior to formation of the phosphor
as described below. In some embodiments substrate 1710 comprises
silicon and all or a portion of silicon substrate 1710 may be
removed prior to phosphor formation as described below. Such
removal may be performed by, e.g., chemical etching, laser lift
off, mechanical grinding and/or chemical-mechanical polishing or
the like. In some embodiments substrate 1710 is used as a template
for growth of the active layers of the device, for example layers
1720, 1730 and 1740. In some embodiments, in use, substrate 1710
provides mechanical support but does not provide an electrical or
optical function and may be removed. In some embodiments removal of
substrate 1710 during the formation process for the white die
includes removal of all or a portion of substrate 1710 that does
not provide electrical functionality (e.g., does not contribute to
the emission or detection of light).
[0159] As shown in FIGS. 17A and 17B, in preferred embodiments LEE
1700 is patterned and etched (e.g., via conventional
photolithography and etch processes) such that a portion of layer
1720 is exposed in order to facilitate electrical contact to layer
1720 and layer 1740 on the same side of LEE 1700 (and without, for
example, the need to make contact to layer 1720 through substrate
1710 or to make contact to layer 1720 with a shunt electrically
connecting a contact pad over layer 1740 to layer 1720). One or
more portions of layers 1730, 1740 are removed (or never formed) in
order to expose a portion of layer 1720, and thus FIG. 17A depicts
a surface 1725 of LEE 1700 that is non-planar, i.e., contains
exposed portions non-coplanar with each other. Surface 1725
corresponds to the outer surface of LEE 1700, including any contour
or topography resulting from portions of layers not being present.
In order to facilitate electrical contact to LEE 1700, discrete
electrical contacts 1760, 1770 are formed on layers 1740, 1720,
respectively. Electrical contacts 1760, 1770 may each include or
consist essentially of a suitable conductive material, e.g., one or
more metals or metal alloys conductive oxides, or other suitable
conductive materials and are generally non-coplanar (particularly
in embodiments when having approximately equal thicknesses), as
depicted in FIG. 17A. In some embodiments surface 1725 is planar or
substantially planar. In some embodiments the top surfaces of
electrical contacts 1760 and 1770 are coplanar or substantially
coplanar. The structure shown in FIGS. 17A and 17B is for
illustrative purposes. There are a wide variety of designs for LEE
210 or LEE 1700, and the specific design of LEE 210 or LEE 1700 is
not a limitation of the present invention. For example, in some
embodiments LEE 210 or LEE 1700 may have different shaped contacts,
different area contacts, different approaches to contact the
semiconductor material or the like.
[0160] In some embodiments, LEE 1700 has a square shape, while in
other embodiments LEE 1700 has a rectangular shape. The shape and
aspect ratio are not critical to the present invention, however,
and LEE 1700 may have any desired shape. In various embodiments,
the extent of one or both of contacts 1760, 1770 in one dimension
(e.g., a diameter or side length) is less than approximately 100
.mu.m, less than approximately 70 lam, less than approximately 35
.mu.m, or even less than approximately 20 .mu.m. In one embodiment,
contacts 1760, 1770 are rectangular and may have a length in the
range of about 10 .mu.m to about 250 .mu.m and a width in the range
of about 5 .mu.m to about 50 .mu.m. In other embodiments, contacts
1760, 1770 have any shape or size, and in some embodiments LEE 1700
has more than two contacts. The number, shape and aspect ratio of
the contacts are not critical to the present invention; however,
and contacts 1760, 1770 may have any desired number, shape and/or
size. In some embodiments, contacts 1760 and 1770 are separated as
far as possible within the geometry of LEE 1700. For example, in
one embodiment the separation between contacts 1760 and 1770 is in
the range of about 75% to over 90% of the length of LEE 1700,
however the separation between contacts is not a limitation of the
present invention.
[0161] In some embodiments where electrical contact to contacts
1760, 1770 is facilitated via use of a conductive adhesive rather
than, e.g., wire bonding, soldering, ultrasonic bonding,
thermosonic bonding or the like, contacts 1760, 1770 may have a
relatively small geometric extent since adhesives may be utilized
to contact even very small areas impossible to connect with wires
or ball bonds (which typically require bond areas of about 80 .mu.m
on a side). The method of die attach is not a limitation of the
present invention and in other embodiments any die-attach method,
for example solder, wire bonding, solder bump, stud bump,
thermosonic bonding, ultrasonic bonding or the like may be used. In
some embodiments one or more contacts, for example contacts 1760
and/or 1770 may include stud bumps or solder bumps.
[0162] Particularly if LEE 1700 includes or consists essentially of
a light-emitting device such as a LED or laser, contacts 1760, 1770
may be reflective to a wavelength of light emitted by LEE 1700) and
hence reflect emitted light back toward substrate 1710. In some
embodiments, a reflective contact 1760 covers a portion or
substantially all of layer 1740, while a reflective contact 1770
covers a portion or substantially all of layer 1720. In addition to
or instead of reflective contacts, a reflector (not shown in this
figure for clarity) may be disposed between or above portions of
contacts 1760, 1770 and over portions or substantially all of layer
1740 and 1720. The reflector is reflective to at least some or all
wavelengths of light emitted by LEE 1700 and may include or consist
essentially of various materials. In one embodiment, the reflector
is non-conductive so as not to electrically connect contacts 1760,
1770. The reflector may be a Bragg reflector. The reflector may
include or consist essentially of one or more conductive materials,
e.g., metals such as silver, gold, platinum, etc. Instead of or in
addition to the reflector, exposed surfaces of semiconductor die
except for contacts 1760, 1770 may be coated with one or more
layers of an insulating material, e.g., a nitride such as silicon
nitride or an oxide such as silicon dioxide. In some embodiments,
contacts 1760, 1770 include or consist essentially of a bond
portion for connection to a circuit board or power supply or the
like and a current-spreading portion for providing more uniform
current through LEE 1700, and in some embodiments, one or more
layers of an insulating material are formed over all or portions of
LEE 1700 except for the bond portions of contacts 1760, 1770.
Insulating material 1750 may include or consist essentially of, for
example, polyimide, silicon nitride, silicon oxide and/or silicon
dioxide. Such insulating material 1750 may cover all or portions of
the top and sides of LEE 1700 as well as all or portions of the top
and sides of layers 1720, 1730 and 1740. Insulating material 1750
may act to prevent shorting between contacts 1760 and 1770 and
between conductors to which contacts 1760 and 1770 may be
electrically coupled.
[0163] FIG. 18 shows one embodiment of white die 200 comprising an
LEE 1700 as described above. White die 200 as shown in FIG. 18 may
be manufactured in accordance with any of various embodiments of
the present invention. As shown in FIG. 18, LEE 1700 includes an
optional reflective layer 1810.
[0164] Advantageously, embodiments of the present invention produce
white dies 200 having controlled binder thickness, uniformity and
distribution of phosphor particles in the binder around LEE 210,
for example a uniform or substantially uniform thickness and
uniform or substantially uniform distribution of phosphor particles
in the binder, or an engineered thickness and distribution of
phosphor particles to achieve uniform or otherwise specified
optical characteristics. The thickness and distribution, or
loading, of the phosphor particles may have a strong impact on the
uniformity of the color temperature of the light. In systems with a
plurality of LEEs, and in particular arrays with tens to thousands
of LEEs, it may be difficult to achieve such phosphor coating over
all of the LEEs when utilizing conventional phosphor-integration
techniques, resulting in non-uniform optical characteristics. FIG.
19 is a schematic of the CIE chromaticity diagram with the
blackbody locus 1910 and an ellipse 1920 representing one or more
MacAdam ellipses. The major axis of MacAdam ellipse 1920 is labeled
as 1940 while the minor axis is labeled as 1930. A MacAdam ellipse
represents a region of colors on the chromaticity chart and a
one-step MacAdam ellipse represents the range of colors around the
center of the ellipse that are indistinguishable to the average
human eye, from the color at the center of the ellipse. The contour
of a one-step MacAdam ellipse therefore represents barely
noticeable differences of chromaticity.
[0165] Multiple-step MacAdam ellipses may be constructed that
encompass larger ranges of color around the center point. The black
body locus is in general aligned with the major axis of a MacAdam
ellipse, meaning that the eye is less sensitive to color
differences along the black body line, which equates to red/blue
shifts, than to differences perpendicular to the black body line,
which equates to a green/magenta shift. Furthermore, with respect
to phosphor-converted white light sources, the variation in the
minor axis direction 1930 is in large measure determined by the LEE
(typically a LED) wavelength variation, while the variation in the
major axis direction 1940 may be largely determined by the phosphor
concentration and thickness. While there are many recommendations
as to how tight the color temperature uniformity should be (as
measured by MacAdam ellipses or other units), it is clear that a
variation encompassed within a smaller step number of MacAdam
ellipses (smaller ellipse) is more uniform than one encompassed
within a larger step number of MacAdam ellipses (larger ellipse).
For example, a four-step MacAdam ellipse encompasses about a 300K
color temperature variation along the black body locus, centered at
3200K, while a two-step MacAdam ellipse encompasses about a 150K
color temperature variation along the black body locus, centered at
3200K.
[0166] The importance of uniform and/or controlled or engineered
thickness and phosphor concentration in white die 200 may be seen
in relation to the MacAdam ellipse on the chromaticity chart of
FIG. 19. Since the major axis length is largely determined by the
phosphor concentration and thickness, variations in these
parameters result in an increase in the major axis of the MacAdam
ellipse and thus an increase in the variation in color temperature.
The aforementioned method for fabrication of uniform thickness and
composition phosphor as part of white die 200 results in a
reduction in the variation in color temperature and thus a more
uniform color temperature light source, both within a lighting
system featuring an array of phosphor-converted LEEs, as well as
between such lighting systems. The use of the aforementioned LEEs
in lighting systems featuring large arrays of LEE permits the
manufacture of large numbers of lighting systems having uniform
color temperatures. In some embodiments, white dies 200 are
manufactured that have a distribution of color temperature less
than 500K, or less than 250K or less than 125K or less than 75K. In
some embodiments, white dies 200 are manufactured that have a
variation in color temperature or chromaticity of less than four
MacAdam ellipses, or less than two MacAdam ellipses, or less than
one MacAdam ellipse. In some embodiments, such tight distributions
are achieved within one white wafer, or within a batch of white
wafers or within the entire manufacturing distribution.
[0167] One step in the method of manufacture of some embodiments of
the present invention is to dispense, cast, pour or otherwise form
a phosphor over LEE on a base. In one embodiment of the present
invention, the amount of phosphor formed is controlled manually by
controlling the dispensing process. For example, the phosphor may
be poured over the LEE and the base. However, this approach may not
provide the desired level of control of the amount of phosphor
formed. Various methods may be used to improve the control and
accuracy of the formation process. For example, in one embodiment a
mold or barrier walls are formed around the LEE. This results in a
volume defined by the area of the mold and the desired phosphor
height. The phosphor may be dispensed by volume, for example from a
calibrated syringe, pipette or other volumetric dispensing system,
to provide the desired volume of phosphor in the mold area. In
another example, the mold may be on a scale and the phosphor may be
dispensed until a certain weight of phosphor has been formed. The
mold volume along with the phosphor density may be used to
calculate the required weight of phosphor to achieve the desired
phosphor amount or coverage.
[0168] In another embodiment, the mold height is adjusted to match
the desired amount of phosphor to be formed, and the
phosphor-formation process may be stopped when the phosphor reaches
the top of the mold or a certain height of the sidewall of the
mold. Such a process may be performed manually or automatically.
For example, automatic control may be accomplished using a camera
that views the edge of the mold and modulates and/or stops the
phosphor-filling process when the phosphor reaches a certain height
relative to the mold wall or top surface of the mold.
[0169] In one embodiment, the thickness of the phosphor is
controlled by feedback during the filling or dispensing process. In
one embodiment, the phosphor is excited by an appropriate pump
source, for example a LEE such as a LED or laser and the resulting
white light color temperature measured (i.e., from the emission
from the phosphor or phosphor and LEE). When the target white light
color temperature is reached, the fill mechanism is notified to
stop the filling or dispensing process. FIG. 20 shows an example of
such an embodiment, featuring base or mold 410, a reservoir 2040 of
phosphor 420, phosphor 420 also in mold 410, valve 2030, a pump
source 2010 and a detector 2020. The target color temperature is
compared to that measured by detector 2020, and when the target
color temperature is reached, detector 2020 sends a signal to close
valve 2030, stopping further dispensing of phosphor 420 into mold
410. In some embodiments, detector 2020 and valve 2030 control in
an on-off configuration while in other embodiments a proportional
control, for example a metering valve, is used. In some
embodiments, an offset in the timing or valve-control signal is
included to accommodate hysteresis or delays in the mold-filling
process. Mold 410 may be transparent or have a transparent region
or window to a wavelength of light emitted by pump source 2010. In
one embodiment, phosphor 420 is excited from the top rather than
through mold 410. In one embodiment, pump source 2010 has a
spectral power distribution the same as, substantially the same as
or similar to that of LEE 210. In one embodiment, pump source 2010
includes or consists essentially of one or more LEE 210. In one
embodiment, mold 410 consists essentially of base 410. In one
embodiment, mold 410 includes or consists essentially of base 410
and sidewalls or barriers 450, as shown in FIG. 4. In one
embodiment, reservoir 2040 and valve 2030 are replaced by a
pressure-assisted dispense system. FIG. 20 shows one pump source
2010, one detector 2020 and one reservoir 2040 with valve 2030;
however, this is not a limitation of the present invention, and in
other embodiments a plurality of any one or more of these features
may be utilized. The method of dispense and/or control is not a
limitation of the present invention. FIG. 20 shows one
configuration of such a filling control scheme; however, other
configurations may be employed, and the specific configuration is
not a limitation of the present invention.
[0170] In one embodiment, one or more LEEs 210 are themselves
energized to provide the source of pump radiation. After phosphor
420 is deposited or dispensed, it may be cured and the resulting
structure processed as described in accordance with any of various
embodiments described herein. In some embodiments, a combination of
formation techniques is used. For example, in one embodiment a
portion of phosphor 420 is formed or dispensed in a manual fashion
or without feedback. This first portion may be cured or partially
cured. Then, a second portion of phosphor 420 is dispensed or
formed under feedback control.
[0171] In some embodiments, it is desirable to keep phosphor 420
level to ensure a uniform layer of phosphor 420 over LEE 210. In
one embodiment, this is done by providing a mechanically level
surface on which base or mold 410 or the like is positioned. In one
embodiment, the level surface is formed within an oven that is used
for curing or partially curing phosphor 420. In one embodiment,
base or mold 410 or the like is floated upon a liquid in a larger
container. FIG. 21 shows an example of this embodiment featuring a
container 2100, mold 410, phosphor 420, LEE 210 and a liquid 2120.
Even if container 2100 is not level, the surface 2110 of liquid
2120 will be level due to gravity, resulting in floating mold 410
being level. This will then result in phosphor 420 in mold 410
being level. In one embodiment, phosphor 420 is activated to aid in
the leveling process. Such activation may include shaking,
vibrating, rocking, agitation, ultrasonificiation or the like.
[0172] In one embodiment, an active feedback leveling system is
used to ensure that base or mold 410 or the like is level. Such a
system, in one example, includes one or more level sensors 2210, an
optional controller 2220 and one or more actuators 2230 acting to
level base or mold 410 or a support on which base or mold 410 is
placed, as shown in FIG. 22. Level sensor 2210 senses the
orientation of base or mold 410 and sends a signal to controller
2220. Controller 2220 utilizes the signal from the one or more
level sensors 2210 to determine and send appropriate actuation
signals to actuators 2230 to make base or mold 410 level or
substantially level. Level sensor 2210 may be, for example, a
physical level sensor or a solid-state or micromachined level
sensor or the like. Actuator 2230 may include or consist
essentially of a piezoelectric translator, a mechanical translator,
an electromechanical translator or the like. The type of level
sensor and/or actuator and/or controller is not a limitation of the
present invention.
[0173] In some embodiments, the physical layout of white dies 200
discussed herein makes them amenable to transfer or pick-and-place
operations of multiple units at a time. As discussed above, some
embodiments of the present invention result in regular periodic
arrays of white dies 200 on a base, for example base 410, from
which a multiple-tool pick-and-place or stamp operation may be fed
with almost 100% utilization of all white dies 200 in the array,
where the pick or stamp pitch is an integer multiple of the pitch
of white dies 200 in the source array.
[0174] FIGS. 23-25 show additional embodiments of the present
invention related to processing and/or removal or partial removal
of the substrate associated with LEE 210. As shown in FIG. 17A, LEE
1700 may include a substrate 1710. As discussed above, substrate
1710 may include or consist essentially of sapphire, silicon
carbide, silicon, GaAs, or the like.
[0175] In some embodiments it may be advantageous to remove all or
a portion of substrate 1710 from LEE 1700. In some examples
substrate 1710 is absorbing or partially absorbing to a wavelength
of light emitted by LEE 1700 (for example where substrate 1710
includes silicon, silicon carbide, or GaAs) and removing or
partially removing substrate 1710 may result in a larger amount of
light being emitted from LEE 1700 because of decreased or no
absorption in substrate 1710. In one embodiment LEE 1700 may
include a III-nitride based light emitter grown on a silicon
substrate. Even in examples where substrate 1710 is transparent or
partially transparent to a wavelength of light emitted by LEE 1700
(for example where substrate 1710 includes sapphire or silicon
carbide), removal of substrate 1710 may be advantageous. For
example, removal or partial removal of substrate 1710 may result in
a reduction or elimination of scattering and absorption in
substrate 1710, with the result that the light from LEE 1700 is
substantially emitted from a plane, rather than a volume (where the
volume emission is mainly from substrate 1710). This may also
permit a smaller white die 200 because the size of phosphor 230 may
be reduced around the periphery of LEE 1700, as shown in FIGS. 23A
and 23B.
[0176] Substrate 1710 may be removed using a variety of techniques,
for example including lapping, grinding, polishing, exfoliation,
ablation, wet chemical etching, dry etching, for example reactive
ion etching, laser lift off, radiation-enhanced lift-off or the
like. The method of removal of substrate 1710 is not a limitation
of the present invention. In one embodiment, substrate 1710
includes or consists essentially of sapphire and layer 1720
includes or consists essentially of GaN, and substrate 1710 is
removed using laser lift-off or other techniques. In one
embodiment, substrate 1710 includes or consists essentially of
silicon and layer 1720 includes or consists essentially of GaN, and
substrate 1710 is removed using one or more of exfoliation,
grinding, lapping, polishing, wet chemical etching or dry chemical
etching or other techniques. In one example the process of
substrate removal may be inserted between the steps associated with
FIGS. 4A and 4B. FIG. 24A shows the structure of FIG. 4A, but
identifying substrate 1710 and device 2410 as part of LEE 210 or
LEE 1700 (in one embodiment, with respect to FIG. 17A, device 2410
comprises LEE 1700 less substrate 1710). FIG. 24B shows the
structure of FIG. 24A at a later stage of manufacture, but before
the step shown in FIG. 4B. FIG. 24B shows the structure of FIG. 24A
after removal of substrate 1710, for example by using laser
lift-off. Other embodiments may include only partial removal of
substrate 1710. FIG. 24C shows the structure of FIG. 24B at a later
stage of manufacture, corresponding to the step shown in FIG. 4B,
after phosphor 420 has been formed over device 2410 and base 410.
At this point the process may continue as discussed above in
reference to FIGS. 4B-4E. In some embodiments, a plurality of steps
are used to remove substrate 1710. For example, a portion of
substrate 1710 may be removed by grinding and/or lapping prior to
singulation of LEE 210 and mounting on base 410. The remaining
portion of substrate 1710 may then be removed using wet or dry
chemical etching. In some embodiments substrate removal may include
only removal of a portion of the substrate, while in other
embodiments substrate removal includes removal of all or
substantially all of the substrate.
[0177] In some embodiments, light is internally reflected within
substrate 1710 and/or layer 1720, in particular in layer 1720 if
substrate 1710 has been removed. Such reflection is called total
internal reflection (TIR) and may reduce the amount of light
exiting LEE. TIR typically occurs because of the index of
refraction differences between adjacent layers and/or substrate or
between the external layer or substrate and the adjacent material,
for example binder, phosphor, air or the like.
[0178] Various approaches may be used to reduce TIR and provide
increased light extraction from substrate 1710 and/or layer 1720,
for example by patterning or roughening the external surface of
these layers or patterning or roughening the interface between
substrate 1710 and layer 1720 or forming an layer over the outside
surface having an index of refraction between those of the two
adjacent materials. In one embodiment, substrate 1710 is patterned
before formation of layer 1720. In the case where substrate 1710
includes sapphire, this may be called patterned sapphire substrate
(PSS). PSS may be formed using etching or a combination of
patterning and etching. Etching may be done by wet chemical
etching, dry etching, for example RIE, ablation or the like. The
method of formation of the PSS is not a limitation of the present
invention. FIG. 25 shows an embodiment of a white die 200 featuring
a PSS 2510. Patterning of substrate 1710 before formation of layer
1720 typically results in the formation of a minor image of the
pattern in the adjacent surface of layer 1720.
[0179] PSS may also be used in combination with laser lift-off to
form a structure similar to that shown in FIG. 23A or FIG. 23B, but
with a patterned external surface of layer 1720, as shown in FIG.
26. As discussed above, growth of layer 1720 on PSS 1710 typically
forms the minor-image pattern in the adjacent surface of layer
1720. Laser lift-off may then be used to remove PSS 1710, leaving a
patterned surface 2610. Such a process may be carried out using the
approach described in reference to FIG. 24A-24C, where LEE 210 in
FIG. 24A comprises a substrate 1710 featuring PSS, as described
above. Substrate 1710 is then removed, as shown in FIG. 24B, and
phosphor 230 formed, as described above, resulting in the white die
structure shown in FIG. 26.
[0180] Patterning or roughening of the external surface of LEE 210
adjacent to phosphor 230 may be accomplished by other techniques,
and may be applied to LEE 210 both with and without substrate 1710.
In one embodiment, the outside surface of substrate 1710 is
patterned or roughened before formation of phosphor 230. Such
patterning or roughening may be done at various points in the
process, for example when LEEs 210 are in wafer form or after
singulation. Such patterning or roughening may also be applied to
the layer adjacent to phosphor 230 in the case where substrate 1710
has been removed, for example layer 1720 in FIGS. 23A and 23B. Such
patterning or roughening may be done by using for example ablation,
wet chemical etching, dry etching, for example reactive ion
etching, laser etching or the like, either alone or in combination
or in combination with patterning. As discussed above, the external
surface of phosphor 230 may also be patterned or roughened to
reduce TIR within phosphor 230. Such patterning or roughening may
be done during the formation process of phosphor 230, as described
above, or after formation of phosphor 230, for example ablation,
wet chemical etching, dry etching, for example reactive ion
etching, molding, imprinting, indentation, cutting, laser etching
or the like, either alone or in combination or in combination with
patterning. In some embodiments such patterning and/or roughening
may be applied to portions of LEE 210 other than the substrate
side, for example to all or portions of the sidewalls and/or
top.
[0181] In yet another embodiment, substrate 1710 may include a
plurality of layers or materials, for example silicon on sapphire,
silicon on a ceramic material such as SiC or AlN, GaN on sapphire,
GaN on a ceramic material such as SiC or AlN or the like. In this
case, one or more of the above processes may be applied to a
multilayer substrate 1710, for example to remove one or more
portions or layers of substrate 1710, or to increase light
extraction by reducing TIR.
[0182] Embodiments of the present invention permit the manufacture
of very large arrays of white dies 200 in an economical manner with
relatively narrow output characteristics. In some embodiments, the
spacing between LEEs 210 in the array is determined by the desired
amount of phosphor on the sides of LEEs 210 and the kerf of the
method used for separating white dies 200. In some embodiments, the
amount of phosphor on the sides of LEEs 210 may range from about 10
.mu.m to about 1000 .mu.m, while the kerf may range from about 2
.mu.m to about 200 .mu.m. The size of LEEs 210 may range from about
10 .mu.m to about 2000 .mu.m or more. The size of LEEs 210, the
width of phosphor on the sides of LEEs 210 and the kerf width are
not limitations of the present invention. As an example, in one
embodiment an LEE 210 has a size of about 375 .mu.m on a side, the
phosphor thickness on the sides of LEE 210 is about 100 .mu.m and
the kerf is about 25 .mu.m, resulting in a space between LEEs 210
of about 225 .mu.m. This results in a white die size of about 575
.mu.m and a pitch of about 600 .mu.m. This leads to a density of
white dies of about 2.77/mm.sup.2 or about 275 white die per square
cm. The manufacturing approaches described above may be practiced
on any arbitrary size area. In one embodiment, the area is about 10
cm.times.about 10 cm, or about 1000 cm.sup.2. In this example, this
leads to the ability to manufacture 275,000 white dies 2610
simultaneously. This is just one example and not meant to be
limiting to the invention. In general the density of white dies 200
will vary with the size of LEEs 210, the kerf and the amount of
phosphor required on the sides of LEEs 210. In another example
white dies 200 may have a size of 975 .mu.m, and a pitch of about
1000 .mu.m or about 1 mm, resulting in a density of about 100 white
dies 200 per square cm and the ability to manufacture about 100,000
white dies 200 simultaneously in an area of about 10 cm.times.about
10 cm. In some embodiments white dies 200 may each comprise a
plurality of LEEs 210, for example a 5.times.5 or 10.times.10 or
10.times.20 array associated with one phosphor 230. The number of
LEEs or size of the white dies are not limitations to the present
invention.
[0183] As will be appreciated by those with ordinary skill in the
art, white dies 210 may be made using a wide range of processes,
while still within the bounds of the present invention. For
example, the table below shows a non-exclusive list of process
steps that may be selected from and used in various orders to
manufacture white dies 200.
TABLE-US-00001 Test LEEs Sort and bin LEEs Virtual sort and bin
LEEs (generate wafer maps) Singulate LEEs Transfer LEE wafer
Transfer singulated LEEs Prepare phosphor Form phosphor over LEEs
Cure phosphor Form optic over white die Test white wafer Singulate
white wafer Sort and bin white dies Sort and bin white wafers
Virtual sort and bin white wafers Test white dies
[0184] FIG. 27 shows one embodiment of a lighting system or portion
of a lighting system 2700 featuring white dies 200. Lighting system
2700 includes an LEE substrate 2720 over which conductive traces
2730 have been formed. White dies 200 are then formed or placed
over conductive traces 2730 such that contacts 220 on LEE 210 are
electrically coupled with conductive traces 2730. In the example in
FIG. 27, white dies 200 are electrically coupled to conductive
traces 2730 using material 2740, which may include or consist
essentially of a conductive adhesive, an anisotropic conductive
adhesive (as disclosed in U.S. patent application Ser. No.
13/171,973, filed Jun. 29, 2011, the entire disclosure of which is
incorporated by reference herein), a combination of conductive and
non-conductive adhesives, conductive epoxy or the like. In one
embodiment, the adhesive is reflective to a wavelength of light
emitted by either or both of LEE 210 and phosphor 230. However, the
method of electrical coupling and attachment of LEE 210 or white
die 200 to conductive traces 2730 is not a limitation of the
present invention and in other embodiments other methods of
electrical coupling and attachment may be used.
[0185] LEE substrate 2720 may include or consist essentially of a
semicrystalline or amorphous material, e.g., polyethylene
naphthalate (PEN), polyethylene terephthalate (PET), acrylic,
polycarbonate, polyethersulfone, polyester, polyimide,
polyethylene, and/or paper. LEE substrate 2720 may also include or
consist essentially of a rigid or flexible circuit board, for
example FR4, metal core printed circuit board (MCPCB), polyimide or
the like. LEE substrate 2720 may be substantially flexible,
substantially rigid or substantially yielding. In some embodiments,
the substrate is "flexible" in the sense of being pliant in
response to a force and resilient, i.e., tending to elastically
resume an original configuration upon removal of the force. A
substrate may be "deformable" in the sense of conformally yielding
to a force, but the deformation may or may not be permanent; that
is, the substrate may not be resilient. Flexible materials used
herein may or may not be deformable (i.e., they may elastically
respond by, for example, bending without undergoing structural
distortion), and deformable substrates may or may not be flexible
(i.e., they may undergo permanent structural distortion in response
to a force). The term "yielding" is herein used to connote a
material that is flexible or deformable or both.
[0186] LEE substrate 2720 may include multiple layers, e.g., a
deformable layer over a rigid layer, for example, a semicrystalline
or amorphous material, e.g., PEN, PET, polycarbonate,
polyethersulfone, polyester, polyimide, polyethylene, paint,
plastic film and/or paper formed over a rigid or substantially
rigid substrate for example including, ceramic such as AlN,
fiberglass, such as FR-4, metal core printed circuit board,
acrylic, aluminum, steel and the like. In some embodiments, LEE
substrate 2720 is rigid or substantially rigid, for example
including ceramic such as AlN, fiberglass, such as FR-4, metal core
printed circuit board, acrylic, aluminum, steel and the like.
[0187] Depending upon the desired application for which embodiments
of the invention are utilized, LEE substrate 2720 is substantially
optically transparent, translucent, or opaque. For example, LEE
substrate 2720 may exhibit a transmittance or a reflectivity
greater than about 80% for optical wavelengths ranging between
approximately 400 nm and approximately 700 nm. In some embodiments,
LEE substrate 2720 exhibits a transmittance or a reflectivity of
greater than about 80% for one or more wavelengths emitted by LEE
210 and/or white die 200. LEE substrate 2720 may also be
substantially insulating, and may have an electrical resistivity
greater than approximately 100 ohm-cm, greater than approximately
1.times.10.sup.6 ohm-cm, or even greater than approximately
1.times.10.sup.10 ohm-cm.
[0188] Conductive traces 2730 may include or consist essentially of
any conductive material, for example metals such as gold, silver,
aluminum, copper, carbon and the like, conductive oxides, carbon,
etc. Conductive traces 2730 may be formed on LEE substrate 2720 by
a variety of techniques, for example evaporation, sputtering,
physical deposition, chemical vapor deposition, plating,
electroplating, printing, lamination, gluing using an adhesive,
lamination and patterning or the like. In one embodiment,
conductive traces 2730 are formed using printing, for example
screen printing, stencil printing, flexo, gravure, ink jet, or the
like. Conductive traces 2730 may include or consist essentially of
silver, aluminum, copper, gold, carbon inks, or other conductive
inks or the like. Conductive traces 2730 may include or consist
essentially of a transparent conductor, for example, a transparent
conductive oxide such as indium tin oxide (ITO). Conductive traces
2730 may include or consist essentially of a plurality of
materials. Conductive traces 2730 may optionally feature stud bumps
to aid in electrical coupling of conductive trace 2730 to contacts
220. Conductive traces 2730 may have a thickness in the range of
about 0.05 .mu.m to about 100 .mu.m; however, this is not a
limitation of the present invention, and in other embodiments
conductive traces 2730 may have any thickness. While the thickness
of one or more of the conductive traces 2730 may vary, the
thickness is generally substantially uniform along the length of
the conductive trace 2730 to simplify processing. However, this is
not a limitation of the present invention and in other embodiments
the conductive trace thickness or material varies.
[0189] In one embodiment, one or more white dies 200 are
electrically coupled to conductive traces 2730 using a conductive
adhesive, e.g., an isotropically conductive adhesive and/or an
anisotropically conductive adhesive (ACA). An ACA is a material
that permits electrical conduction only in the vertical direction
but insulates the conductive trace 2730 from each other. As used
here, ACA may be an anisotropic conductive material in any form,
for example paste, gel, liquid, film or otherwise. ACAs may be
utilized with or without stud bumps.
[0190] The systems described above may be combined with additional
electronics to form an electronic device 2800 as shown in FIG. 28.
In one embodiment, the device includes a plurality of white dies
200 that are electrically coupled to traces 2730. As shown,
electronic device 2800 includes three serially-connected strings
2810 of white dies 200. Electronic device 2800 also includes
circuitry 2820 electrically connected to one or more of strings
2810. Circuitry 2820 may include or consist essentially of portions
or substantially all of the drive circuitry, sensors, control
circuitry, dimming circuitry, and or power-supply circuitry or the
like, and may also be adhered (e.g., via an adhesive) or otherwise
attached to substrate 2720. In one embodiment, the power supply and
driver are distributed, e.g., the device 2800 may have a
centralized power supply and all or a portion of the drive
circuitry distributed in different locations. Circuitry 2820 may
even be disposed on a circuit board (e.g., a printed circuit board)
that itself may be mechanically and/or electrically attached to
substrate 2730. In other embodiments, circuitry 2820 is separate
from substrate 2730. In some embodiments circuitry 2820 is formed
on substrate 2730. While FIG. 28 depicts white dies 200
electrically coupled in serially connected in strings 2810, and
strings 2810 connected or connectable in parallel, other
die-interconnection schemes are possible and within the scope of
embodiments of the invention.
[0191] As shown in FIG. 28, the lighting system 2800 may feature
multiple strings, each string 2810 including or consisting
essentially of a combination of one or more white dies 200
electrically connected in series, in parallel, or in a
series-parallel combination with optional fuses, antifuses,
current-limiting resistors, zener diodes, transistors, and other
electronic components to protect white die 200 from electrical
fault conditions and limit or control the current flow through
individual white dies 200. In general, such combinations feature an
electrical string that has at least two electrical connections for
the application of DC or AC power. A string may also include a
combination of one or more white dies 200 electrically connected in
series, in parallel, or in a series-parallel combination of white
dies 200 without additional electronic components. FIG. 28 shows
three strings of white dies 200, each string having three white
dies 200 in series; however, this is not a limitation of the
present invention, and in other embodiments the number of strings
is less than or greater than three and the number of white dies 200
in a string is greater or less than three. In one embodiment, a
string includes at least ten white dies 200. In one embodiment, a
string includes at least 45 white dies 200. In one embodiment,
system 2800 includes at least ten strings. In one embodiment,
system 2800 includes at least 50 strings.
[0192] In some embodiments, variations in optical characteristics
of LEEs 210 are accommodated during the fabrication of white dies
200. In one embodiment, where the variation in the optical
characteristic, for example wavelength, is relatively monotonic or
known or predictable across the physical layout of LEEs 210, mold
3110 may be tilted or terraced or sloped to provide a variation in
thickness of phosphor 420 over LEE 210, as shown generically in
FIG. 29 before curing of phosphor 420. A feedback system similar to
that shown in FIG. 20 may be used to determine the optimum tilt
value. In another embodiment, the tilt is determined from a map of
the characteristics of the array of LEEs 210. In another
embodiment, the tilt is introduced manually. In another embodiment,
the bottom surface is terraced, for example by conforming it to a
terraced chuck, e.g., a terraced vacuum chuck. In FIG. 29, LEE 210'
receives a thicker phosphor layer thereover than does LEE 210''.
After the proper tilt is achieved, phosphor 420 is cured and the
resulting structure may be processed as described elsewhere in this
description. The example shown in FIG. 29 shows a tilted mold 410,
however in other embodiments mold 410 is terraced.
[0193] In one embodiment of this aspect of the invention, the
spacing between LEEs 210, and thus the amount of phosphor 230
surrounding the sides of an LEE 210, is substantially constant. In
one embodiment, the spacing between LEEs 210, and thus the amount
of phosphor 230 surrounding the sides of LEEs 210, is chosen to be
the maximum required for the array of LEEs 210 under fabrication.
In one embodiment, the cutting or separation process produces
phosphor 230 of different sizes, in relation to a feedback system
or a prior input, for example a map of one or more optical
characteristics. For example a laser-based cutting system may be
directed to cut different size phosphors 230 around different LEEs
210, based on some form of input, for example, feedback, a map,
etc.
[0194] FIG. 30 shows another embodiment of a system to optimize the
phosphor and LEE combination. LEEs 210 may be placed on a film or
base 3010. A barrier 3015 is optionally present to contain phosphor
420. LEEs 210 are energized to provide a signal to a detector 3030.
The signal is then sent to a controller 3040 that controls a series
of actuator pins 3020 on an actuator base 3025. If more phosphor is
desired above a particular LEE 210, the associated actuator pin
3020 may move down or remain in place. For LEEs 210 that require
less phosphor above them, the associated actuator pin 3020 may move
up or remain in place. In one embodiment, all LEEs 210 are actuated
simultaneously and detector 3030 simultaneously detects the light
from each LEE 210 and its surrounding phosphor 420. In one
embodiment, each LEE 210 is energized separately. Thus, detector
3030 may be a fixed or moveable detector, or a stage upon which
actuator base 3010 is positioned may be moved relative to detector
3030. After all actuator pins 3020 are in their correct position,
phosphor 420 may be cured and the resulting structure processed as
described elsewhere in this description. In one embodiment actuator
pins 3020 are controlled in response to a map of the
characteristics of LEEs 210.
[0195] Structures such as those discussed in relation to FIG. 12 or
that utilize shaped or textured phosphor may also be manufactured
by an additive or subtractive process, carried out during or after
the formation of white dies 200. For example, in some embodiments a
white die 200 having any shape is subsequently shaped by addition
of more phosphor either uniformly or selectively over portions of
white die 200. In some embodiments, a white die 200 having any
shape is subsequently shaped by removal of one or more portions of
phosphor either uniformly or selectively over portions of white die
200.
[0196] In some embodiments of the present invention it may be
desirable to facilitate removal of the white dies or white die
wafer from mold substrate 410. For example in some cases the
adhesion of phosphor to mold substrate 410 may be relatively high
and reduction of the adhesion may facilitate the manufacturing
process. In some embodiments mold substrate 410 may be formulated
or treated to have difference levels of adhesion to facilitate
various aspects of the process. For example, mold substrate 410 may
have regions of relatively higher adhesion under LEEs 210 and
regions of relatively lower adhesion in the areas between LEEs 210.
In some embodiments this may facilitate adhesion of LEEs 210 to
mold substrate 410 during the initial steps in the process, while
also facilitating removal of the white dies or white die wafer from
mold substrate 410 after the phosphor is cured or partially cured.
FIGS. 31A-31C show one embodiment of such an approach, starting
with FIG. 31A, in which LEEs 210 are formed over mold substrate
410. FIG. 31B shows the structure of FIG. 31A at a later stage of
manufacture, in which the structure is treated using treatment 3100
to reduce the adhesion level of mold substrate 410 in general or to
phosphor 230 in particular. FIG. 31C shows the structure of FIG.
31B after treatment 3100, with regions 3110 having relatively
reduced adhesion after treatment 3100. In some embodiments,
treatment 3100 may be a plasma treatment, a wet chemical treatment,
exposure to radiation or the like. In some embodiments treatment
3100 may include formation of a material, for example a mold
release compound on mold substrate 410, to facilitate removal of
the white dies or white die wafer after the phosphor is cured. In
some examples of this embodiment, the material that was formed on
the top of LEEs 210 during treatment 310 (if any) may be left in
place, while in others the material formed on the top of LEEs 210
may be removed before formation of phosphor 230. The specific
treatment 3100 is not a limitation of the present invention.
[0197] FIGS. 31A-31C show one embodiment using LEEs 210 as the mask
for treatment 3100; however, this is not a limitation of the
present invention, and in other embodiments other approaches may be
used. For example a stencil or mask may be applied to or over mold
substrate 410 to provide the pattern for application of treatment
3100. In one embodiment treatment 3100 is applied selectively,
without the need for a stencil or mask. For example treatment 3100
may be applied by an applicator on an x-y stage that is moved over
mold substrate 410, or mold substrate 410 may be moved under a
fixed applicator. In one embodiment the adhesion may be reduced by
removal of all or a portion of the adhesive layer or component on
mold substrate 410. In different embodiments this may be done by
spraying, dispensing, scraping or the like.
[0198] In another embodiment a film may be selectively applied to
mold substrate 410 that has reduced adhesion to cured phosphor 230.
FIGS. 32A and 32B show one embodiment of such an approach. FIG. 32A
shows LEEs 210 on mold substrate 410. A film 3210, for example a
mold release film, has been selectively applied to this structure.
Application may be done before or after provision of LEEs 210 on
mold substrate 410. In some embodiments film 3210 includes a
cut-out or hole which leaves an open area for positioning of LEEs
210 directly on mold substrate 410 while in other cases the cut-out
permits overlaying film 3210 on mold substrate 410 after LEEs 210
are formed on mold substrate 410. FIG. 32B shows the structure of
FIG. 32A after application and curing of phosphor 320. As may be
seen, this structure may facilitate the removal of white dies
(after singulation) or the white die wafer because the regions
including film 3210 have reduced adhesion to phosphor 230.
[0199] In one embodiment film 3210 may be used as a method to
control die and/or contact relief, as shown schematically in FIGS.
33A and 33B. FIG. 33A shows a close-up view of one die from FIG.
32B showing the thickness of film 3210 relative to the edge of LEE
210. The thickness of film 3210 may be adjusted to achieve a
certain die relief 950, as shown in FIG. 33B for the white die of
FIG. 33A after singulation and removal from mold substrate 410. In
one embodiment film 3210 may be spaced apart from the edge of LEE
210, as shown in FIG. 33C to produce a white die with a stepped die
relief 950, as shown in FIG. 33D.
[0200] In some embodiments mold substrate 410 may be composed of
more than one material, where each of the materials is optimized
for a specific purpose. For example FIG. 34 shows mold substrate
410 having portions 3410 and 3420. In one embodiment portion 3410
is optimized to have an adhesive level appropriate to hold LEEs 210
in place during the process, while portion 3420 is optimized to
have an adhesive level low enough to permit facile removal of cured
phosphor 230.
[0201] In yet another embodiment mold substrate 410 includes or
consists essentially of a compressible or deformable material, into
which all or a portion of the contacts and/or a portion of LEE 210
may be embedded, as shown in FIGS. 35A and 35B. FIG. 35A shows all
or portions of the contacts embedded into mold substrate 410, while
FIG. 35B shows the contacts and a portion of the sidewall of the
die embedded into mold substrate 410. In some embodiments this may
be used as a way to control die and/or contact relief. In some
embodiments the deformable layer may comprise an adhesive layer on
mold substrate 410, while in other embodiments the deformable layer
may not have substantial adhesion to LEEs 210. In one embodiment
the mold substrate is patterned or structured to control the die
relief; for example, the mold substrate may have an indentation
into which a portion of LEE 210 is inserted, as shown in FIG.
36.
[0202] While the discussion above has focused on reduction of
adhesion in the regions adjacent to LEEs 210, other approaches may
be utilized, for example to increase the adhesion in the region
under LEEs 210. For example, mold substrate 410 may have a
relatively low adhesion, in particular to phosphor 230, but then
may not have sufficient adhesion to hold LEEs 210 in place during
the process. In some embodiments, such a mold substrate 410 may be
treated to increase the adhesion level in the region under LEEs
210. For example, in one embodiment an adhesive may be selectively
deposited on a "non-stick" mold substrate 410. In some embodiments
selective application of an adhesive may be done by screen
printing, stencil printing, selective spraying, application of
adhesive tape or the like.
[0203] In one embodiment mold substrate 410 includes a plurality of
holes to which are applied a vacuum. LEEs 210 are placed over the
holes and held in place by vacuum applied to the holes as shown in
FIG. 37. FIG. 37 shows mold substrate 410 with holes 3710 that are
connected by way of connection 3720 to a source of vacuum or a
vacuum pump. LEEs 210 are held in place by the application of
vacuum and then after formation of the white dies or white die
wafer the vacuum is removed, facilitating removal of the white dies
or white die wafer. While the schematic of FIG. 37 shows one vacuum
hole 3710 for each LEE 210, this is not a limitation of the present
invention, and in other embodiments each LEE 210 may be associated
with more than one vacuum hole 3710. In some embodiments an
optional material may be positioned on mold substrate 410 between
vacuum holes 3710. The optional material may include a mold release
compound, mold release film or other material or film that prevents
phosphor 230 from sticking to mold substrate 410.
[0204] In some embodiments it may be advantageous to position a
second material, for example a pliable or deformable material,
between mold substrate 410 and all or a portion of each LEE 210. In
one embodiment the pliable or deformable material may facilitate
the vacuum seal to LEE 210, improving the adhesion of LEE 210 to
mold substrate 410. In one embodiment the pliable or deformable
material facilitates removal of the cured white die or white die
wafer from mold substrate 410.
[0205] In one embodiment mold substrate 410 combines the vacuum
holes and a stepped structure, as shown in FIG. 38. FIG. 38 also
shows optional second material 3810. In one embodiment the
structure of FIG. 38 may be used to control the die and/or contact
relief. In some embodiments various elements of the approaches
described in relation to the mold substrate may be used in
combination or in an order different from that discussed
herein.
[0206] In the structures discussed above LEE 210 is shown as
including a substrate, for example substrate 1710 of FIG. 17A;
however, this is not a limitation of the present invention, and in
other embodiments the substrate may be partially or completely
removed. FIGS. 39A and 39B show schematics of two possible
embodiments of white die 3900, 3901, where LEE 3910 has the
substrate partially or completely removed. In FIG. 39A, phosphor
230 covers all or substantially all of the top surface but very
little or none of the sides of LEE 3910, while in FIG. 39B phosphor
230 covers all or substantially all of the top surface and at least
portions of the sides of LEE 3910. In some embodiments, removal of
the substrate results in no or very little side emission from LEE
3910, and thus all of the light is emitted from the top surface of
LEE 3910. In this case, as shown in FIG. 39A, it may be possible to
achieve the desired optical characteristics by covering only all or
a portion of the top surface of LEE 3910 with phosphor 230. In an
embodiment where side emission still occurs, phosphor may be formed
on all or a portion of the sidewall of LEE 3910, as shown in FIG.
39B.
[0207] In some embodiments substrate 1710 may include or consist
essentially of, e.g., silicon or sapphire or gallium arsenide. In
one embodiment the starting structure comprises a III-nitride based
LED on a silicon substrate. In one embodiment the starting
structure comprises a III-arsenide/phosphide based LED on a gallium
arsenide substrate.
[0208] FIGS. 40A-40C show one method for manufacture of structures
like those shown in FIGS. 39A and 39B. FIG. 40A shows a wafer of
LEEs that includes substrate 1710 and device layers 4010 formed
over mold substrate 410. In some embodiments device layers 4010 may
comprise layers 1720, 1730 and 1740 from FIG. 17A. In FIG. 40A, LEE
3910 is identified by an encircling dashed line and in some
embodiments comprises all of structure 1700 from FIG. 17A with the
exception of all or a part of substrate 1710. FIG. 40B shows the
structure of FIG. 40A at a later stage of manufacture, after
substrate 1710 has been removed. In other embodiments the structure
of FIG. 40B may include a portion of substrate 1710. FIG. 40C shows
the structure of FIG. 40B at a later stage of manufacture, after
formation and curing of phosphor 230 and singulation into white die
3900.
[0209] Substrate 1710 may be removed by a variety of means, for
example using chemical etching, dry etching, reactive ion etching,
laser lift-off, lapping, polishing, exfoliation or the like--the
method of removal of substrate 1710 is not a limitation of the
present invention. In some embodiments a combination of methods may
be used to remove substrate 1710. In some embodiments a selective
removal process, for example a selective etch, or an etch stop
layer, may be used to facilitate removal of substrate 1710.
[0210] FIG. 40D shows a portion of one embodiment of a method to
make white die 3901 of FIG. 39B. In this embodiment, all or a
portion of layers 4010 are removed between adjacent LEEs. In some
embodiments a portion of substrate 1710 may also be removed. In
this embodiment removal occurs before formation over mold substrate
410. As may be seen, after substrate 1710 is completely or
partially removed, phosphor 230 is formed and cured and singulated,
the resulting structure is that of white die 3901, as shown in FIG.
39B. In another embodiment the substrate 1710 with the LEEs 210
thereon is singulated before transfer to mold substrate 410
(similar to the structure shown in FIG. 4A) and then substrate 1710
is completely or partially removed while the LEEs are on the mold
substrate 410. The method and order of removing substrate 1710
relative to formation of phosphor 230 is not a limitation of the
present invention.
[0211] While the structures shown in FIGS. 39A and 39B each include
one LEE 3910, this is not a limitation of the present invention,
and in other embodiments white die 3900 and 3901 may each include a
plurality of LEEs 3901, as shown in FIGS. 40E and 40F. Furthermore,
any or all of the techniques and approaches described herein for
white dies 210 with substrate 1710 may be applied to white dies
without all or a portion of substrate 1710.
[0212] In some embodiments the white die wafer may be singulated in
a batch or semi-batch mode. In one embodiment white dies are
singulated using a rotary cutter, for example a circular blade
similar to that of a pizza-cutting tool. In one embodiment multiple
blades may be ganged together on a common shaft to make multiple
cuts simultaneously, reducing singulation time. In some embodiments
a custom one-piece blade having multiple cutting surfaces may be
utilized. Such parallelism may be used for other approaches, for
example dicing or sawing or laser cutting or water jet cutting. Die
cutting, in which a die is manufactured that singulates all or a
group of white die simultaneously is another batch singulation
technique that may be utilized in embodiments of the present
invention.
[0213] In some embodiments the blade used for singulation may be
angled to form a sloped sidewall of the white die. In some
embodiments a shaped blade may be used to impart a shape to the
white die, as shown in FIGS. 41A and 41B, where blade 4100 is shown
to have two exemplary shapes, resulting in complementary shapes in
phosphor 230.
[0214] In some embodiments the phosphor may be shaped to provide a
surface or a portion of a surface to facilitate a transfer
operation, for example a pick-and-place operation. For example, a
structure with a curved phosphor surface may have a flat portion to
facilitate pick-up using a vacuum tool. In some embodiments one or
more features may be formed in the phosphor to act as identifying
marks or fiducial marks that may be recognized by semi-automated or
automated equipment. For example, in some embodiments such
alignment of fiducial marks may be used by an automated
pick-and-place tool to identify and orient the white dies for
pick-up as well as for placement on a wiring board. Such
orientation may include locating the center of the white die, the
position of the contacts, or the polarity of the white die (i.e.,
which contact is the p-contact and which is the n-contact). FIGS.
42A-42D depict some examples of such fiducial marks, including
chamfers (FIG. 42A), grooves (FIG. 42B), raised regions (FIG. 42C),
and sloped surfaces (FIG. 42D). These examples are meant to
demonstrate the concept but not be limiting to the invention. Such
features may be designed to be visible by cameras or vision
systems, or to reflect light differently from the rest of the
surface of white die 210 and thus facilitate identification of the
white die as well as its orientation and position. Such alignment
of fiducial features may be formed as part of the white die
formation process. For example, such features may be part of the
mold, or they may be formed after curing or partial curing of
phosphor 230, e.g., by laser cutting, indentation, ablation or the
like. The method of formation of the fiducial marks is not a
limitation of the present invention.
[0215] In one embodiment of the present invention a reflecting
layer is formed on all or a portion of the bottom surface of white
die 210 to reflect light back in a direction away from the
contacts. FIG. 43 shows a white die 4300 that includes reflecting
layer 4310. Reflecting layer 4310 may be reflective to a wavelength
of light emitted by phosphor 230 and/or LEE 210. In some
embodiments reflecting layer 4310 has a reflectivity greater than
25% to a wavelength of light emitted by phosphor 230 and/or LEE
210. In some embodiments reflecting layer 4310 has a reflectivity
greater than 50% to a wavelength of light emitted by phosphor 230
and/or LEE 210. In some embodiments reflecting layer 4310 has a
reflectivity greater than 75% to a wavelength of light emitted by
phosphor 230 and/or LEE 210.
[0216] There are a number of ways in which a reflecting layer may
be formed. In one embodiment a powder of a material that is
reflective to a wavelength of light emitted by phosphor 230 and/or
LEE 210 is dispersed over mold substrate 410 after formation of LEE
210 on mold substrate 410, as shown in FIG. 44. As seen in FIG. 44,
this may result in a portion 4410 of the powder on top of LEE 210
and a portion 4420 of the powder directly on mold substrate 410. In
some embodiments powder 4420 may adhere to mold substrate 410 but
not adhere well to the top of LEE 210, and the structure shown in
FIG. 44 may be tilted, inverted, exposed to a jet of gas, shaken or
otherwise processed to remove powder 4410 on top of LEEs 210. The
white die formation process may then be applied to the structure
shown in FIG. 44, resulting in white die 4300 (FIG. 43) where
reflecting layer 4310 is composed of the reflecting powder. In some
embodiments the reflective powder may include at least one of fumed
silica, fumed alumina, TiO.sub.2 or the like; however, the
composition of the reflective powder is not a limitation of the
present invention. In some embodiments powder 4410 is formed of
particles that have a dimension in the range of about 1 .mu.m to
about 50 .mu.m; however, the size of the powder particles is not a
limitation of the present invention. In some embodiments the layer
of phosphor into which is adhered, embedded or infused powder 4410
has a thickness in the range of about 0.1 .mu.m to about 30 .mu.m;
however, the thickness of this layer is not a limitation of the
present invention.
[0217] Another aspect of this approach is that it may be used to
modify the adhesion of cured phosphor 230 to mold substrate 410,
similar to what has been described elsewhere herein. For example,
if the reflective layer is formed from a powder, the powder may
also reduce the adhesion of cured phosphor 230 to mold substrate
410. If the reflective layer is a film, as discussed subsequently,
it may act to or be engineered to reduce the adhesion of cured
phosphor 230 to mold substrate 410, similar to the discussion
related to the mold release film.
[0218] In another embodiment of this approach, the reflecting layer
is formed using a reflective film. For example, a reflecting film
4510, similar to a mold release film, may be positioned over a
portion of mold substrate 410, as shown in FIG. 45A. After
formation and curing of phosphor 230 (FIG. 45B) and singulation
(FIG. 45C), reflecting film 4510 adheres to and/or is embedded into
cured phosphor 230 of the white die instead of acting to reduce
adhesion between cured phosphor 230 and mold substrate 410, as is
the case with the mold release film. As discussed herein, the film
may by itself or in combination with other approaches be used to
control die and contact relief. In some embodiments reflective film
4510 includes metal films or foils such as Cr, Al, Au, Ag, Cu, Ti,
or the like. In some embodiments reflective film 4510 may have a
thickness in the range of about 0.25 .mu.m to about 50 .mu.m;
however, the thickness of reflective film 4510 is not a limitation
of the present invention. In some embodiments reflective film 4510
is not thick enough to occlude light emitted from the side(s) of
LEE 210. In one embodiment reflective film 4510 is a foil that has
been patterned with holes corresponding to the position of LEEs 210
on mold substrate 410.
[0219] In one embodiment reflective layer 4310 may be deposited on
mold substrate 410 and patterned to permit positioning of LEEs 210
directly on mold substrate 410. In one embodiment reflective layer
4310 may be applied selectively to mold substrate 410, for example
through a shadow mask or selectively applied by evaporation,
sputtering, spraying, or the like. In one embodiment a reflecting
layer may be formed by printing, for example screen, stencil, ink
jet, gravure, flexo printing or the like. In one embodiment
reflective layer 4310 may be composed of more than one layer of
materials, for example a carrier and a reflective layer. In another
embodiment reflective layer 4310 may be applied to the white wafer
after it is formed. For example reflective layer 4310 could be
formed by selective deposition of a reflecting layer on the bottom
of the white wafer, where the reflective material is formed such
that it does not come in electrical contact with any portion of the
electrical contacts of LEEs 210. In some embodiments this may be
done by deposition of a metal layer, for example, Cr, Al, Au, Ag,
Cu, Ti or the like, for example by evaporation, physical vapor
deposition, sputtering, chemical vapor deposition, plating or the
like. In some embodiments it may be accomplished by lamination of a
patterned foil.
[0220] In some embodiments, reflective layer 4310 may be insulating
or relatively insulating. For example, reflective layer 4310 may
include a dielectric minor or Bragg reflector, composed of
alternating layers of materials with different indices of
refraction. Examples of such materials include silicon dioxide,
silicon nitride, or mixtures of these materials.
[0221] Reflective layer 4310 may be a specular or diffuse
reflector. For example a reflective layer 4310 made from powder may
provide a more diffuse reflector while a reflective layer 4310 made
from a metal foil or film may provide a more specular reflector.
Reflective layer 4310 may also include or consist essentially of a
diffuse reflective film, such as a white film, for example white
PET, other white plastic films, White97 manufactured by WhiteOptics
LLC, or MCPET manufactured by Furukawa. In some embodiments a white
ink or paint may be applied selectively to the back of the white
wafer to form reflective layer 4310. While application of materials
has been discussed for application to the white wafer, such
materials may be applied to the back of singulated white dies.
[0222] In some embodiments the molding of the phosphor to the die
may be combined with one or more other processes. For example, in
one embodiment an optical element (e.g., a lens) may be co-molded
or molded simultaneously to the white die. Such structures are
shown in FIGS. 46A-46C. FIG. 46A shows an example of a white die
incorporating optical element 4610, while FIGS. 46B and 46C show
examples of white dies with an optical element 4610 in which the
substrates of the light-emitting elements have been partially or
completely removed.
[0223] In one embodiment structures like those shown in FIGS.
46A-46C may be formed by adding an array of optical elements to the
mold top 1031 during the process for white die fabrication. FIG.
47A shows an optical array 4710 of optical elements between mold
top 1031 and phosphor 230. FIG. 47B shows white dies on mold
substrate 410 incorporating optical elements 4610 after curing of
the phosphor 230 and singulation. In some embodiments, optical
element 4610 may be a Fresnel lens or a conventional lens. In some
embodiments optical element 4610 may initially be part of an array
of optical elements such as optical array 4710 as discussed above,
while in other embodiments one or more optical elements 4610 may be
positioned individually in the formation process. In one embodiment
optical array 4710 may be all or a portion of the mold top
1031.
[0224] In another embodiment optical array 4710 may be joined to a
white die wafer 4810 after fabrication of white die wafer 4810, as
shown in FIG. 48. In one embodiment phosphor 230 of white die wafer
4810 may be partially cured, mated to optical array 4710, and then
be subjected to additional curing to physically attach optical
array 4710 to white die wafer 4810. In one embodiment an adhesive
may be used to attach optical array 4710 to white die wafer 4810.
Examples of adhesives include optical adhesives, spray adhesives,
adhesive tape, polyurethane, the same material used as the binder
for phosphor 230, or the like. The method of attachment of optical
array 4710 to white die wafer 4810 is not a limitation of the
present invention. In some embodiments the adhesive has an index of
refraction that provides index matching between phosphor 230 and
optical array 4710. In some embodiments, after attachment of
optical array 4710 to white die wafer 4810, singulation takes place
to separate the structure into smaller elements, each containing at
least one LEE 210 and one optical element 4610.
[0225] As shown, optical array 4710 includes or consists
essentially of one or more optical elements 4610, which in FIGS.
47A and 50 are aligned or substantially aligned with white dies
200. Optical array 4710 typically features an array of optical
elements 4610; in some embodiments, one optical element 4610 is
associated with each white die 200, while in other embodiments
multiple white dies 200 are associated with one optical element
4610, or multiple optical elements 4610 are associated with a
single white die 200, or no engineered optical element is
associated with any white die 200, for example all or portions of
optical array 4710 may be a plate with a flat or roughened surface.
In one embodiment, optical array 4710 includes elements or features
to scatter, diffuse and/or spread out light generated by white dies
200.
[0226] Optical array 4710 may be substantially optically
transparent or translucent. For example, optical array 4710 may
exhibit a transmittance greater than 80% for optical wavelengths
ranging between approximately 400 nm and approximately 600 nm. In
one embodiment, optical array 4710 includes or consists essentially
of a material that is transparent to a wavelength of light emitted
by white dies 200. Optical array 4710 may be substantially flexible
or rigid. In some embodiments, optical array 4710 includes multiple
materials and/or layers. Optical elements 4610 may be formed in or
on optical array 4710. Optical array 4710 may include or consist
essentially of, for example, acrylic, polycarbonate, polyethylene
naphthalate (PEN), polyethylene terephthalate (PET), polycarbonate,
polyethersulfone, polyester, polyimide, polyethylene, silicone,
glass, or the like. Optical elements 4610 may be formed by etching,
polishing, grinding, machining, molding, embossing, extruding,
casting, or the like. The method of formation of optical elements
4610 is not a limitation of embodiments of the present
invention.
[0227] Optical elements 4610 associated with optical array 4710 may
all be the same or may be different from each other. Optical
elements 4610 may include or consist essentially of, e.g., a
refractive optic, a diffractive optic, a total internal reflection
(TIR) optic, a Fresnel optic, or the like, or combinations of
different types of optical elements. Optical elements 4610 may be
shaped or engineered to achieve a specific light distribution
pattern from the array of light emitters, phosphors and optical
elements.
[0228] As used herein, "alignment" and "aligned" may mean that the
center of one structure, for example a white die 200, is aligned
with the center of another structure, for example an optical
element 4610; however, this is not a limitation of the present
invention, and in other embodiments, alignment refers to a
specified relationship between the geometry of multiple
structures.
[0229] While the discussion above has mainly focused on
light-emitting devices that include a phosphor, this approach may
be used as an approach to economically make light-emitting devices
without the phosphor, where the material surrounding the LEE is a
transparent material 4910 with no light-conversion material, as
shown in FIGS. 49A-49E. This may be called a "clear die" 4900. In
this case the transparent material may be called a binder or an
encapsulant. In this case the structure would appear similar to the
examples discussed above, with the difference being that there is
no light-conversion material present and the light emitted by such
device is that emitted by the LEE. In some embodiments other
materials may be present in the binder, for example material to
scatter the light. FIGS. 49A-49E show examples of clear dies 4900
that include LEEs 210 and binder or encapsulant 4910. Any or all of
the variations discussed with respect to this invention may be used
to produce clear dies. This approach permits the low-cost
manufacture of clear dies in very large volumes. In some
embodiments LEE 210 may include or consist essentially of an LED.
In some embodiments LEE 210 may emit light in any visible color
range, for example, red, orange, yellow, green, amber, blue, etc.,
or in wavelengths outside of the visible range, e.g., infrared and
ultraviolet. FIGS. 49A-49C show examples of clear dies 4900 with
various shapes of binder 4910, while FIG. 49D shows an example of a
clear die with a co-molded optical fiber 4920. Optical fiber 4920
may be used for example, for out-coupling of light or monitoring of
LEE 210 optical characteristics. Such optical fiber coupling may
also be used with white dies. FIG. 49E shows clear die 4900
integrated with an optical element 4610, as discussed above with
respect to white dies.
[0230] FIGS. 50-58 present different embodiments of the present
invention that feature one or more optical elements. FIG. 50 shows
the structure of FIGS. 27 and 28 with integrated optical elements.
In FIG. 50, each white die 200 has associated therewith an optical
element 4610.
[0231] As shown, an optic 5010 includes or consists essentially of
one or more optical elements 4610, which in FIG. 50 are aligned or
substantially aligned with white dies 200. Optic 5010 typically
features an array of optical elements 4610; in some embodiments,
one optical element 4610 is associated with each white die 200,
while in other embodiments multiple white dies 200 are associated
with one optical element 4610, or multiple optical elements 4610
are associated with a single white die 200, or no engineered
optical element is associated with any white die 200, for example
optic 5010 may be a plate with a flat or roughened surface. In one
embodiment, optic 5010 includes elements or features to scatter,
diffuse and/or spread out light generated by white dies 200.
[0232] Optic 5010 may be substantially optically transparent or
translucent. For example, optic 5010 may exhibit a transmittance
greater than 80% for optical wavelengths ranging between
approximately 400 nm and approximately 600 nm. In one embodiment,
optic 5010 includes or consists essentially of a material that is
transparent to a wavelength of light emitted by white dies 200.
Optic 5010 may be substantially flexible or rigid. In some
embodiments, optic 5010 is composed of multiple materials and/or
layers. Optical elements 4610 may be formed in or on optic 5010.
Optic 5010 may include or consist essentially of, for example,
acrylic, polycarbonate, polyethylene naphthalate (PEN),
polyethylene terephthalate (PET), polycarbonate, polyethersulfone,
polyester, polyimide, polyethylene, silicone, glass or the like.
Optical elements 4610 may be formed by etching, polishing,
grinding, machining, molding, embossing, extruding, casting, or the
like. The method of formation of optical elements 4610 is not a
limitation of embodiments of the present invention.
[0233] Optical elements 4610 associated with optic 5010 may all be
the same or may be different from each other. Optical elements 4610
may include or consist essentially of, e.g., a refractive optic, a
diffractive optic, a total internal reflection (TIR) optic, a
Fresnel optic, or the like, or combinations of different types of
optical elements. Optical elements 4610 may be shaped or engineered
to achieve a specific light distribution pattern from the array of
light emitters, phosphors and optical elements.
[0234] The space 5020 between the back side of optic 5010 and white
die 200, shown in FIG. 50, may be a partial vacuum or be filled
with air, filled with a fluid or other gas or filled or partially
filled with one or more other materials. In one embodiment, region
5020 is filled or partially filled with a transparent material,
similar or identical to the material that is used as the binder for
phosphor 230, to reduce TIR losses in white dies 200 and to provide
enhanced optical coupling between white dies 200 and optics
4610.
[0235] The structure shown in FIG. 51 is similar to that shown in
FIG. 50; however, in FIG. 51, depressions 5100 are formed in optic
5010, to accommodate or partially accommodate white dies 200. White
dies 200 may be formed or inserted into depressions 5100, for
example in a batch process or using a pick-and-place tool. White
dies 200 may be held in depressions 5100 mechanically, or with an
adhesive or glue. In one embodiment, white dies 200 are held in
place by a transparent material similar or identical to the binder
or matrix used with phosphor 230. In one embodiment, depression
5100 is larger than white die 200. In one embodiment, depression
5100 is sized to just accommodate white die 200. FIGS. 52 and 53
show components of the structure of FIG. 51 at an early stage of
manufacture. FIG. 52 shows optic 5010 with depressions 5100. FIG.
53 shows LEE substrate 2720, conductive traces 2730 and white dies
200. These two structures shown in FIGS. 52 and 53 are mated
together to form the structure in FIG. 51.
[0236] The structure shown in FIG. 54 is similar to that shown in
FIG. 51; however, in the case of the structure of FIG. 54, white
dies 200 are formed or placed into depressions 5100 in optic 5010
with the contacts facing out, and conductive traces 2730 are formed
over optic 5010 and contacts 220, electrically coupling white dies
200. In this embodiment, LEE substrate 2720 is eliminated.
Conductive traces 2730 may be formed using a variety of methods,
for example physical vapor deposition, evaporation, sputtering,
chemical vapor deposition, lamination, lamination and patterning,
plating, printing, ink jet printing, screen printing, gravure
printing, flexo printing or the like. In one embodiment, a
reflective surface 5410 is formed over the back of optic 5010 so
that all or a substantial or controlled portion of light emitted
from the back side of white dies 200 is reflected back toward
optics 4610. The reflective surface 5410 may include a metal such
as gold, silver, aluminum, copper or the like and may be deposited
by evaporation, sputtering, chemical vapor deposition, plating,
electroplating or the like, or may include a reflective coating
such as paint, ink or the like, for example white ink or white
paint. If the reflective coating is electrically conductive, it may
be isolated from conductive traces 2730 or may be isolated from
(e.g., removed in) the regions occupied by conductive traces 2730.
The reflective coating may be non-conductive. The reflective
coating may be formed either over or under conductive traces 2730.
The reflective coating may cover all or portions of white dies 200
and/or conductive traces 2730. The reflective coating may also
include other materials, e.g., a Bragg reflector, or one or more
layers of a specular or diffuse reflective material. In one
embodiment, optic 5010 is backed with a reflective material, e.g.,
White97 manufactured by WhiteOptics LLC or MCPET manufactured by
Furukawa, or any other reflective material. In one embodiment,
conductive traces 2730 include or are formed of a material
reflective to a wavelength of light emitted by white dies 200 and
are patterned to provide a region of reflective material
surrounding white dies 200. The use of such reflective materials,
or a reflective LEE substrate 2720, may be applied to any
configuration of light system, for example those shown in FIGS.
50-57. FIG. 55 shows the structure of FIG. 54 at an early stage of
manufacture, prior to formation of conductive traces 2730 and
optional reflective layer 5410.
[0237] The structures shown in FIGS. 56 and 57 are similar to that
shown in FIG. 54; however, in this case conductive traces 2730 are
formed over optic 5010 before formation or placement of white dies
200, as shown in FIG. 56. After formation or placement of white
dies 200 in depressions 5100, contacts 220 on white dies 200 are
electrically coupled to conductive traces 2730 using jumpers (i.e.,
discrete conductors) 5710. Jumpers 5710 may be formed by a variety
of different techniques. In one embodiment, conductive material is
formed and patterned over the surface of optic 5010, for example by
evaporation, sputtering, lamination, plating, or the like, and
patterning may be performed using photolithography, shadow mask,
stencil mask, or the like. In one embodiment, jumpers 5710 are
formed by printing, for example by screen printing, stencil
printing, ink jet printing, or the like. In one embodiment jumpers
5710 are formed by wire bonding. Jumpers 5710 may have a
rectangular shape, but this is not a limitation of the present
invention and in other embodiments jumpers 5710 have trapezoidal,
square or any arbitrary shape. Jumpers 5710 may include one or more
conductive materials, for example aluminum, gold, silver, platinum,
copper, carbon, conductive oxides or the like. Jumper 5710 may have
a thickness in the range of about 50 nm to about 100 .mu.m. In one
embodiment, jumper 5710 has a thickness in the range of about 5
.mu.m to about 30 .mu.m. In one embodiment, jumpers 5710 include
materials used for conductive traces 2730 and/or are formed using
methods used for forming conductive traces 2730. The method of
formation and composition of jumper 5710 are not limitations of the
present invention.
[0238] The examples discussed above for white die 200 show one LEE
210 in each white die 200. However, this is not a limitation of the
present invention and in other embodiments each white die 200
includes a plurality of LEE 210.
[0239] The examples discussed above for white dies 200 show white
dies 200 as being square and having sidewalls perpendicular to the
contact face of LEE 210. However, this is not a limitation of the
present invention and in other embodiments white die 200 is
rectangular, hexagonal, circular, triangular, or has any arbitrary
shape, and/or has sidewalls forming any angle with respect to the
surface of LEE 210 including contacts 220. While the term white
die, for example related to white die 200, has been used to
describe a structure producing white light, this is not a
limitation of the present invention, and in other embodiments,
different color LEEs 210 and different phosphors (one or more) may
be used to produce other colors, for example amber, green or any
arbitrary color or spectral power distribution. In other
embodiments, a white die 200 includes a plurality of LEEs 210. In
some embodiments, the LEEs 210 are all the same, while in other
embodiments the LEEs 210 include two or more groups of different
LEEs 210, for example emitting at different wavelengths. In some
embodiments LEE 210 may include or consist essentially of an
organic light emitter.
[0240] While the discussion above has mainly focused on
light-emitting devices, embodiments of the present invention may
also be used for devices that absorb light, for example detectors
or photovoltaic devices. FIG. 58A shows an exemplary device 5800
that includes a light-absorbing element (LAE) 5810 and binder 5820.
In one embodiment LAE 5810 is configured with a flip-chip geometry,
in which contacts 220 are positioned on a face opposite a detecting
face 5830. In one embodiment LAE 5810 has a structure similar to
that for LEE 1700 shown in FIG. 17A. In one embodiment the
substrate for LAE 5810 is partially or completely removed. LAE 5810
may be configured to detect one or more wavelengths over a wide
range of wavelength ranges, both within and outside the visible
light spectrum. In various embodiments LAE 5810 may be configured
to detect UV light, IR light, x-rays, visible light or any portion
of the electromagnetic spectrum for which a detector is available.
In some embodiments LAE 5810 may include GaAs, InAs, AlAs, GaN,
InN, AlN, GaP, InP, AlP, InGaP, InAlP, InGaAlP, ZnO, II-VI
materials or the like or various combinations of two or more of
these materials. The material from which LAE 5810 is composed is
not a limitation of the present invention.
[0241] In some embodiments LAE 5810 may be a Schottky detector, a
p-n junction detector, a photoelectric detector, a photocell, a
photoresistor, a photodiode, a phototransistor, a charge-coupled
device, a CMOS imager or the like. The type of LAE 5810 and method
by which LAE 5810 operates are not limitations of the present
invention.
[0242] In one embodiment binder 5820 is transparent to a wavelength
of light to be detected by LAE 5810. In one embodiment binder 5820
may be partially absorbing and the absorption band of binder 5820
may be used to select one or more wavelength ranges to be detected
by LAE 5810 from the range of incident wavelength ranges. For
example binder 5820 may effectively act as a low-pass filter, a
high-pass filter, a bandpass filter or various combinations of
these.
[0243] In some embodiments binder 5820 may further include other
materials to enhance one or more aspects of the performance of
device 5800. For example in one embodiment binder 5820 may include
materials to absorb one or more wavelengths of light, to act as a
filter. In one embodiment binder 5820 includes a
wavelength-conversion material, similar to that described above. In
one embodiment this may be used to shift an incident wavelength to
a different wavelength to be detected by LAE 5810. For example a
phosphor may be added to binder 5820 to shift one or more
wavelengths of incident light (e.g., blue light) to one or more
different wavelengths (e.g., yellow light) that impinge on LAE
5810. In this way one or a small number of LAEs 5810 may be used in
combination with a number of wavelength-conversion materials to
produce a family of detectors spanning a wide wavelength range,
without the need to have a relatively large number of different
LAEs 5810.
[0244] As discussed herein with respect to white dies, binder 5820
may be shaped. In some embodiments binder 5820 is shaped to
increase the collection of light by LAE 5810. FIG. 58B shows an
example of device 5800 having shaped binder 5820 having a dome-like
shape. In some embodiments shaped binder 5820 is combined with one
or more additives to binder 5820, for example a
wavelength-conversion material.
[0245] In some embodiments device 5800 may include more than one
LAE 5810. In one embodiment device 5800 includes three LAEs 5810,
identified as LAEs 5810, 5810', and 5810'' in FIG. 58C. In one
embodiment LAE 5810 detects red wavelengths, LAE 5810' detects
green wavelengths, and LAE 5810'' detects blue wavelengths, and the
combination may be used as a color sensor by evaluating the
relative output signals from the three different LAEs.
[0246] In some embodiments LAE 5810 is a photovoltaic device or
solar cell, and is designed to produce power from incident
radiation (typically, but not necessarily, in the visible range).
Such a photovoltaic device may be made of a wide variety of
materials. In some embodiments LAE 5810 may include GaAs, InAs,
AlAs, GaN, InN, AlN, GaP, InP, AlP, InGaP, InAlP, InGaAlP, ZnO,
II-VI materials or the like or various combinations of two or more
of these materials. The material from which LAE 5810 is made is not
a limitation of the present invention. In some embodiments LAE 5810
is a single-junction solar cell, while in other embodiments LAE
5810 is a multi-junction solar cell. As discussed herein with
respect to light-emitting elements and detectors, photovoltaic
devices produced using embodiments of the present invention may
include in various embodiments a transparent binder, additives to
the binder, wavelength-conversion materials, shaped binder, optics,
multiple LAEs 5810 per device, and the like.
[0247] In some embodiments a photovoltaic device made using this
invention may additionally include one or more optics to increase
collection or to act as concentrators, for example as shown in FIG.
59A. FIG. 59A shows a device 5900 that includes a solar cell 5910,
a binder 5820, and an optic 4610. In one embodiment the optical
function for collection or concentration is carried out using a
shaped binder 5820, as shown in FIG. 59B for device 5901.
[0248] In some embodiments binder 5820 may further include other
materials to enhance one or more aspects of the performance of
devices 5900, 5901. For example in one embodiment binder 5820 may
include materials to absorb one or more wavelengths of light, to
act as a filter. In one embodiment binder 5820 includes a
wavelength-conversion material, similar to that described above
with respect to white dies. In one embodiment this may be used to
shift an incident wavelength to a different wavelength to be
absorbed by solar cell 5910. For example a phosphor may be added to
binder 5820 to shift one or more wavelengths of incident light to
one or more different wavelengths of light that impinge on solar
cell 5910. In this way a larger portion of the solar spectrum may
be usefully absorbed by solar cell 5910. In some embodiments this
may permit the use of a lower cost solar cell 5910, for example one
with fewer junctions. In one embodiment more than one different
solar cell, each absorbing light in a different wavelength range,
may be incorporated into one packaged device, similar to the
structure shown in FIG. 58C.
[0249] Embodiments of the present invention may be applied to
devices that neither emit nor detect light, identified as
electronic-only devices, where the purpose of application of this
invention is in some embodiments reduction in cost. In various
embodiments, a relatively large number of electronic devices,
specifically chips or discrete devices or integrated circuits may
be packaged in a polymer-based material (like the binder detailed
above) using a high-volume, low-cost, base process. In some
embodiments of this approach, binder 5820 need not be transparent
but may be translucent or opaque. As discussed herein with respect
to light-emitting elements, detectors, and photovoltaic devices,
electronic-only devices produced in accordance with embodiments of
the present invention may include additives to the binder, shaped
binder, multiple devices, and the like.
[0250] In one embodiment an electronic-only device of the present
invention is a packaged electronic only device, such as that shown
in FIG. 60A, in which device 6000 includes electronic-only device
6010 and binder 6020. In some embodiments electronic only device
6010 may have a larger number of contacts than would a light
emitter or a detector. For example electronic-only device 6010 may
include more than ten contacts or more than 100 contacts or even
larger number of contacts.
[0251] FIG. 60B shows another example, device 6001, incorporating a
heat spreader 6030. A heat spreader, as utilized herein, is a
volume of material with a relatively high thermal conductivity, in
particular higher than that of binder 6020, which may be used to
transfer heat from electronic-only device 6010 to ambient or to an
additional thermal-management system. In some embodiments heat
spreader 6030 is a metal, for example Al, Cu, Au, Ag, Cr, or the
like. In some embodiments heat spreader 6030 is a ceramic, for
example AlN, SiC, polycrystalline SiC, polycrystalline AlN, or the
like. In some embodiments heat spreader 6030 is a monolithic
component, but this is not a limitation of the present invention,
and in other embodiments heat spreader 6030 may comprise multiple
discrete and separate portions, as shown in FIGS. 60C and 60D
respectively. While heat spreader 6030 is shown as a square or
rectangle in FIGS. 60C and 60D, this is not a limitation of the
present invention, and in other embodiments heat spreader 6030 may
have any shape or size. In one embodiment heat spreader 6030 is a
heat pipe.
[0252] In another embodiment a connector may be added to a device,
for example an electronic-only device. In one embodiment a
connector 6040 is added on top of electronic-only device 6010 and
held in place at least in part by the presence of binder 6020, as
shown in FIG. 60E.
[0253] In another embodiment one or more devices may be stacked on
top of each other, as shown in FIG. 61. FIG. 61 shows
electronic-only device 6010' formed over electronic-only device
6010. FIG. 61 also shows optional vias through electronic-only
device 6010, permitting electrical coupling between electronic-only
devices 6010' and 6010. Other methods may be used to electrically
couple devices, for example wire bonding, solder, conductive
adhesives, etc. While FIG. 61 shows electronic-only device 6010 and
6010' having different sizes, that is not a limitation of the
present invention and in other embodiments electronic-only device
6010 and electronic-only device 6010' may have the same or
substantially the same size.
[0254] In another embodiment electronic-only and other (for example
light-detecting and/or light-emitting) devices may be packaged in
the same binder, as shown in FIG. 62. FIG. 62 shows electronic-only
device 6010 adjacent to light-detection device 5810. This approach
may be used to provide some additional capability, for example
signal conditioning, communications, memory or the like. In one
embodiment electronic-only device 6010 and light-detection device
5810 communicate through each of their respective contacts by way
of connections on the circuit board to which they are ultimately
mounted. In one embodiment internal connection is used, for example
similar to the vias shown in FIG. 61 or wire bonds, etc.
[0255] While the discussion herein mainly focuses on
down-conversion, that is the use of a wavelength-conversion
material or phosphor to shift a short wavelength to a longer
wavelength, that is not a limitation of the present invention and
in other embodiments up-conversion or a combination of
up-conversion and down-conversion may be used.
[0256] Other embodiments of this invention may have additional or
fewer steps or components or may be modified or carried out in a
different order. In general in the above discussion the arrays of
light emitters, wells, optics and the like have been shown as
square or rectangular arrays; however, this is not a limitation of
the present invention and in other embodiments these elements are
formed in other types of arrays, for example hexagonal, triangular
or any arbitrary array. In some embodiments, these elements are
grouped into different types of arrays on a single substrate.
[0257] The terms and expressions employed herein are used as terms
and expressions of description and not of limitation, and there is
no intention, in the use of such terms and expressions, of
excluding any equivalents of the features shown and described or
portions thereof. In addition, having described certain embodiments
of the invention, it will be apparent to those of ordinary skill in
the art that other embodiments incorporating the concepts disclosed
herein may be used without departing from the spirit and scope of
the invention. Accordingly, the described embodiments are to be
considered in all respects as only illustrative and not
restrictive.
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