US Patent No. 10,153,404

LED WITH HIGH THERMAL CONDUCTIVITY PARTICLES IN PHOSPHOR CONVERSION LAYER


Patent No. 10,153,404
Issue Date December 11, 2018
Title Led With High Thermal Conductivity Particles In Phosphor Conversion Layer
Inventorship Grigoriy Basin, San Jose, CA (US)
Mikhail Fouksman, San Jose, CA (US)
Assignee Lumileds LLC, San Jose, CA (US)

Claim of US Patent No. 10,153,404

1. A method of fabricating a light emitting diode (LED) module comprising:providing a reflective cup containing at least one LED die;
positioning a solid piece on the at least one LED die and within the reflective cup, the solid piece abutting inner walls of the reflective cup to create a void below the solid piece, the solid piece comprising:
a binder;
high thermal conductivity particles, an index of refraction of the binder and an index of refraction of the high thermal conductivity particles being substantially equal, and a thermal conductivity of the high thermal conductivity particles being greater than a thermal conductivity of the binder; and
wavelength conversion particles that convert a wavelength of light emitted by the at least one LED die to a different wavelength,
the wavelength conversion particles and the high thermal conductivity particles being uniformly mixed in the binder;
softening the positioned solid piece to conform to a volume defined by the inner walls of the reflective cup and to encapsulate the at least one LED die to draw heat away from the at least one LED die; and
hardening the softened solid piece after encapsulation of the at least one LED die.