PARTICLE SYSTEMS AND PATTERNING FOR MONOLITHIC LED ARRAYS

Abstract

A wavelength converting layer is disclosed that includes a plurality of phosphor grains 50-500 nm in size and encapsulated in cerium free YAG shells and a binder material binding the plurality of phosphor grains, the wavelength converting layer having a thickness of 5-20 microns attached to the light emitting surface.

Description

BACKGROUND

Precision control lighting applications can require the production and manufacturing of light emitting diode (LED) pixel systems. Manufacturing such LED pixel systems can require accurate deposition of material due to the small size of the pixels and the small lane space between the systems. The miniaturization of components used for such LED pixel systems may lead to unintended effects that are not present in larger LED pixel systems.

Semiconductor light-emitting devices including LEDs, resonant cavity light emitting diodes (RCLEDs), vertical cavity laser diodes (VCSELs), and edge emitting lasers are among the most efficient light sources currently available. Materials systems currently of interest in the manufacture of high-brightness light emitting devices capable of operation across the visible spectrum include Group III-V semiconductors, particularly binary, ternary, and quaternary alloys of gallium, aluminum, indium, and nitrogen, also referred to as III-nitride materials. Typically, III-nitride light emitting devices are fabricated by epitaxially growing a stack of semiconductor layers of different compositions and dopant concentrations on a sapphire, silicon carbide, III-nitride, composite, or other suitable substrate by metal-organic chemical vapor deposition (MOCVD), molecular beam epitaxy (MBE), or other epitaxial techniques. The stack often includes one or more n-type layers doped with, for example, Si, formed over the substrate, one or more light emitting layers in an active region formed over the n-type layer or layers, and one or more p-type layers doped with, for example, Mg, formed over the active region. Electrical contacts are formed on the n- and p-type regions.

III-nitride devices are often formed as inverted or flip chip devices, where both the n- and p-contacts formed on the same side of the semiconductor structure, and most of the light is extracted from the side of the semiconductor structure opposite the contacts.

SUMMARY

The A wavelength converting layer is disclosed that includes a plurality of phosphor grains 50-500 nm in size and encapsulated in cerium free YAG shells and a binder material binding the plurality of phosphor grains, the wavelength converting layer having a thickness of 5-20 microns attached to the light emitting surface.

BRIEF DESCRIPTION OF THE DRAWINGS

A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings wherein:

FIG. 1A is a top view diagram of a 3×3 pixel matrix;

FIG. 1B is a top view diagram of a 10×10 pixel matrix;

FIG. 1C is a diagram of a 3×3 pixel matrix on a sapphire substrate;

FIG. 1D is a cross-section view diagram of an LED array;

FIG. 1E is a cross-section view diagram of a light emitting devices;

FIG. 1F is a top view diagram of a mesh wall;

FIG. 1G is a cross-section view diagram of the mesh wall of FIG. 1F;

FIG. 1H is a cross-section view diagram of a 5-20 micron thick wavelength converting layer with phosphor grains encapsulated by cerium free YAG shells, deposited onto a light emitting device;

FIG. 1I is a flow diagram for depositing a wavelength converting layer;

FIG. 2A is a top view of the electronics board with LED array attached to the substrate at the LED device attach region in one embodiment;

FIG. 2B is a diagram of one embodiment of a two channel integrated LED lighting system with electronic components mounted on two surfaces of a circuit board;

FIG. 2C is an example vehicle headlamp system; and

FIG. 3 shows an example illumination system.

DETAILED DESCRIPTION

Examples of different light illumination systems and/or light emitting diode (“LED”) implementations will be described more fully hereinafter with reference to the accompanying drawings. These examples are not mutually exclusive, and features found in one example may be combined with features found in one or more other examples to achieve additional implementations. Accordingly, it will be understood that the examples shown in the accompanying drawings are provided for illustrative purposes only and they are not intended to limit the disclosure in any way. Like numbers refer to like elements throughout.

It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms may be used to distinguish one element from another. For example, a first element may be termed a second element and a second element may be termed a first element without departing from the scope of the present invention. As used herein, the term “and/or” may include any and all combinations of one or more of the associated listed items.

It will be understood that when an element such as a layer, region, or substrate is referred to as being “on” or extending “onto” another element, it may be directly on or extend directly onto the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or extending “directly onto” another element, there may be no intervening elements present. It will also be understood that when an element is referred to as being “connected” or “coupled” to another element, it may be directly connected or coupled to the other element and/or connected or coupled to the other element via one or more intervening elements. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present between the element and the other element. It will be understood that these terms are intended to encompass different orientations of the element in addition to any orientation depicted in the figures.

Relative terms such as “below,” “above,” “upper,”, “lower,” “horizontal” or “vertical” may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.

Semiconductor light emitting devices (LEDs) or optical power emitting devices, such as devices that emit ultraviolet (UV) or infrared (IR) optical power, are among the most efficient light sources currently available. These devices (hereinafter “LEDs”), may include light emitting diodes, resonant cavity light emitting diodes, vertical cavity laser diodes, edge emitting lasers, or the like. Due to their compact size and lower power requirements, for example, LEDs may be attractive candidates for many different applications. For example, they may be used as light sources (e.g., flash lights and camera flashes) for hand-held battery-powered devices, such as cameras and cell phones. They may also be used, for example, for automotive lighting, heads up display (HUD) lighting, horticultural lighting, street lighting, torch for video, general illumination (e.g., home, shop, office and studio lighting, theater/stage lighting and architectural lighting), augmented reality (AR) lighting, virtual reality (VR) lighting, as back lights for displays, and IR spectroscopy. A single LED may provide light that is less bright than an incandescent light source, and, therefore, multi-junction devices or arrays of LEDs (such as monolithic LED arrays, micro LED arrays, etc.) may be used for applications where more brightness is desired or required.

According to embodiments of the disclosed subject matter, LED arrays (e.g., micro LED arrays) may include an array of pixels as shown in FIG. 1A, 1B, and/or 1C. LED arrays may be used for any applications such as those requiring precision control of LED array segments. Pixels in an LED array may be individually addressable, may be addressable in groups/subsets, or may not be addressable. In FIG. 1A, a top view of a LED array 110 with pixels 111 is shown. An exploded view of a 3×3 portion of the LED array 110 is also shown in FIG. 1A. As shown in the 3×3 portion exploded view, LED array 110 may include pixels 111 with a width w₁ of approximately 100 μm or less (e.g., 40 μm). The lanes 113 between the pixels may be separated by a width, w₂, of approximately 20 μm or less (e.g., 5 μm). The lanes 113 may provide an air gap between pixels or may contain other material, as shown in FIGS. 1B and 1C and further disclosed herein. The distance d₁ from the center of one pixel 111 to the center of an adjacent pixel 111 may be approximately 120 μm or less (e.g., 45 μm). It will be understood that the widths and distances provided herein are examples only, and that actual widths and/or dimensions may vary.

It will be understood that although rectangular pixels arranged in a symmetric matrix are shown in FIGS. 1A, B and C, pixels of any shape and arrangement may be applied to the embodiments disclosed herein. For example, LED array 110 of FIG. 1A may include, over 10,000 pixels in any applicable arrangement such as a 100×100 matrix, a 1200×50 matrix, a symmetric matrix, a non-symmetric matrix, or the like. It will also be understood that multiple sets of pixels, matrixes, and/or boards may be arranged in any applicable format to implement the embodiments disclosed herein.

FIG. 1B shows a cross section view of an example LED array 1000. As shown, the pixels 1010, 1020, and 1030 correspond to three different pixels within an LED array such that a separation sections 1041 and/or n-type contacts 1040 separate the pixels from each other. According to an embodiment, the space between pixels may be occupied by an air gap. As shown, pixel 1010 includes an epitaxial layer 1011 which may be grown on any applicable substrate such as, for example, a sapphire substrate, which may be removed from the epitaxial layer 1011. A surface of the growth layer distal from contact 1015 may be substantially planar or may be patterned. A p-type region 1012 may be located in proximity to a p-contact 1017. An active region 1021 may be disposed adjacent to the n-type region and a p-type region 1012. Alternatively, the active region 1021 may be between a semiconductor layer or n-type region and p-type region 1012 and may receive a current such that the active region 1021 emits light beams. The p-contact 1017 may be in contact with SiO2 layers 1013 and 1014 as well as plated metal (e.g., plated copper) layer 1016. The n type contacts 1040 may include an applicable metal such as Cu. The metal layer 1016 may be in contact with a contact 1015 which may be reflective.

Notably, as shown in FIG. 1B, the n-type contact 1040 may be deposited into trenches 1130 created between pixels 1010, 1020, and 1030 and may extend beyond the epitaxial layer. Separation sections 1041 may separate all (as shown) or part of a wavelength converting layer 1050. It will be understood that a LED array may be implemented without such separation sections 1041 or the separation sections 1041 may correspond to an air gap. The separation sections 1041 may be an extension of the n-type contacts 1040, such that, separation sections 1041 are formed from the same material as the n-type contacts 1040 (e.g., copper). Alternatively, the separation sections 1041 may be formed from a material different than the n-type contacts 1040. According to an embodiment, separation sections 1041 may include reflective material. The material in separation sections 1041 and/or the n-type contact 1040 may be deposited in any applicable manner such as, for example, but applying a mesh structure which includes or allows the deposition of the n-type contact 1040 and/or separation sections 1041. Wavelength converting layer 1050 may have features/properties similar to wavelength converting layer 205 of FIG. 1D. As noted herein, one or more additional layers may coat the separation sections 1041. Such a layer may be a reflective layer, a scattering layer, an absorptive layer, or any other applicable layer. One or more passivation layers 1019 may fully or partially separate the n-contact 1040 from the epitaxial layer 1011.

The epitaxial layer 1011 may be formed from any applicable material to emit photons when excited including sapphire, SiC, GaN, Silicone and may more specifically be formed from a III-V semiconductors including, but not limited to, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, InN, InP, InAs, InSb, II-VI semiconductors including, but not limited to, ZnS, ZnSe, CdSe, CdTe, group IV semiconductors including, but not limited to Ge, Si, SiC, and mixtures or alloys thereof. These example semiconductors may have indices of refraction ranging from about 2.4 to about 4.1 at the typical emission wavelengths of LEDs in which they are present. For example, III-Nitride semiconductors, such as GaN, may have refractive indices of about 2.4 at 500 nm, and III-Phosphide semiconductors, such as InGaP, may have refractive indices of about 3.7 at 600 nm. Contacts coupled to the LED device 1200 may be formed from a solder, such as AuSn, AuGa, AuSi or SAC solders.

The n-type region may be grown on a growth substrate and may include one or more layers of semiconductor material that include different compositions and dopant concentrations including, for example, preparation layers, such as buffer or nucleation layers, and/or layers designed to facilitate removal of the growth substrate. These layers may be n-type or not intentionally doped, or may even be p-type device layers. The layers may be designed for particular optical, material, or electrical properties desirable for the light emitting region to efficiently emit light. Similarly, the p-type region 1012 may include multiple layers of different composition, thickness, and dopant concentrations, including layers that are not intentionally doped, or n-type layers. An electrical current may be caused to flow through the p-n junction (e.g., via contacts) and the pixels may generate light of a first wavelength determined at least in part by the bandgap energy of the materials. A pixel may directly emit light (e.g., regular or direct emission LED) or may emit light into a wavelength converting layer 1050 (e.g., phosphor converted LED, “PCLED”, etc.) that acts to further modify wavelength of the emitted light to output a light of a second wavelength.

Although FIG. 1B shows an example LED array 1000 with pixels 1010, 1020, and 1030 in an example arrangement, it will be understood that pixels in an LED array may be provided in any one of a number of arrangements. For example, the pixels may be in a flip chip structure, a vertical injection thin film (VTF) structure, a multi-junction structure, a thin film flip chip (TFFC), lateral devices, etc. For example, a lateral LED pixel may be similar to a flip chip LED pixel but may not be flipped upside down for direct connection of the electrodes to a substrate or package. A TFFC may also be similar to a flip chip LED pixel but may have the growth substrate removed (leaving the thin film semiconductor layers un-supported). In contrast, the growth substrate or other substrate may be included as part of a flip chip LED.

The wavelength converting layer 1050 may be in the path of light emitted by active region 1021, such that the light emitted by active region 1021 may traverse through one or more intermediate layers (e.g., a photonic layer). According to embodiments, wavelength converting layer 1050 or may not be present in LED array 1000. The wavelength converting layer 1050 may include any luminescent material, such as, for example, phosphor particles in a transparent or translucent binder or matrix, or a ceramic phosphor element, which absorbs light of one wavelength and emits light of a different wavelength. The thickness of a wavelength converting layer 1050 may be determined based on the material used or application/wavelength for which the LED array 1000 or individual pixels 1010, 1020, and 1030 is/are arranged. For example, a wavelength converting layer 1050 may be approximately 20 μm, 50 μm or 1200 μm. The wavelength converting layer 1050 may be provided on each individual pixel, as shown, or may be placed over an entire LED array 1000.

Primary optic 1022 may be on or over one or more pixels 1010, 1020, and/or 1030 and may allow light to pass from the active region 101 and/or the wavelength converting layer 1050 through the primary optic. Light via the primary optic may generally be emitted based on a Lambertian distribution pattern such that the luminous intensity of the light emitted via the primary optic 1022, when observed from an ideal diffuse radiator, is directly proportional to the cosine of the angle between the direction of the incident light and the surface normal. It will be understood that one or more properties of the primary optic 1022 may be modified to produce a light distribution pattern that is different than the Lambertian distribution pattern.

Secondary optics which include one or both of the lens 1065 and waveguide 1062 may be provided with pixels 1010, 1020, and/or 1030. It will be understood that although secondary optics are discussed in accordance with the example shown in FIG. 1B with multiple pixels, secondary optics may be provided for single pixels. Secondary optics may be used to spread the incoming light (diverging optics), or to gather incoming light into a collimated beam (collimating optics). The waveguide 1062 may be coated with a dielectric material, a metallization layer, or the like and may be provided to reflect or redirect incident light. In alternative embodiments, a lighting system may not include one or more of the following: the wavelength converting layer 1050, the primary optics 1022, the waveguide 1062 and the lens 1065.

Lens 1065 may be formed form any applicable transparent material such as, but not limited to SiC, aluminum oxide, diamond, or the like or a combination thereof. Lens 1065 may be used to modify the a beam of light to be input into the lens 1065 such that an output beam from the lens 1065 will efficiently meet a desired photometric specification. Additionally, lens 1065 may serve one or more aesthetic purpose, such as by determining a lit and/or unlit appearance of the multiple LED devices 1200B.

FIG. 1C shows a cross section of a three dimensional view of a LED array 1100. As shown, pixels in the LED array 1100 may be separated by trenches which are filled to form n-contacts 1140. The pixels may be grown on a substrate 1114 and may include a p-contact 1113, a p-GaN semiconductor layer 1112, an active region 1111, and an n-Gan semiconductor layer 1110. It will be understood that this structure is provided as an example only and one or more semiconductor or other applicable layers may be added, removed, or partially added or removed to implement the disclosure provided herein. A wavelength converting layer 1117 may be deposited on the semiconductor layer 1110 (or other applicable layer).

Passivation layers 1115 may be formed within the trenches 1130 and n-contacts 1140 (e.g., copper contacts) may be deposited within the trenches 1130, as shown. The passivation layers 1115 may separate at least a portion of the n-contacts 1140 from one or more layers of the semiconductor. According to an implementation, the n-contacts 1140, or other applicable material, within the trenches may extend into the wavelength converting layer 1117 such that the n-contacts 1140, or other applicable material, provide complete or partial optical isolation between the pixels.

Typical LED wavelength converting layers, especially those emitting red light, may include a luminescent cerium compound emitting bright red light (e.g., Ce doped compound such as, for example CaSiN₂:Ce³+). Such a cerium based compound can be used for white light applications to, for example, enhance the light quality of the system based on a blue LED with a yellow/green phosphor, as the red phosphor in the UV LED plus three RGB phosphors setup or, directly as a yellow phosphor with a 460 nm wavelength emitting LED due to the emission/excitation band shift with chemical substitution. However, the presence of Cerium may impose limitations on an LED device including, for example, physical properties, dimensions, chemical properties, or the like.

FIG. 1D shows an example pixel array 1200 manufactured in accordance with the techniques disclosed herein may include light-emitting devices 1270 that include a GaN layer 1250, active region 1290, solder 1280, and pattern sapphire substrate (PSS) pattern 1260. Wavelength converting layers 1220 may be disposed onto the light emitting devices 1270 in accordance with the techniques disclosed herein to create pixels 1275.

Optical isolation materials 1230 may be applied to the wavelength converting layer 1220. A wavelength converting layer may be mounted onto a GaN layer 1250 via a pattern sapphire substrate (PSS) pattern 1260. The GaN layer 1250 may be bonded to or grown over an active region 1290 and the light-emitting device 1270 may include a solder 1280. Optical isolator material 1240 may also be applied to the sidewalls of the GaN layer 1250.

As an example, the pixels 1275 of FIG. 1D may correspond to the pixels 111 of FIG. 1b. When the pixels 111 or 1275 are activated, the respective active regions 1290 of the pixels may generate a light. The light may pass through the wavelength converting layer 1220 and may substantially be emitted from the surface of the wavelength converting layer 1220.

FIG. 1E shows components of the pixel array of FIG. 1D prior to the wavelength converting layer 1220 being placed on the light emitting devices 1270.

In accordance with an implementation of the disclosed subject matter, FIG. 1F shows a top view and FIG. 1G shows a cross-sectional view of a mesh wall 1215 that may be generated to provide a structure for a wavelength converting layer 1220 of FIG. 1D when manufacturing the LED array of FIG. 1D. The mesh wall 1215 may contain cavities 214 that correspond to the light emitting devices 1270 such that the mesh wall is spaced such that the cavities 214 align spatially with the light emitting devices 1270. The mesh walls may be formed using a nanoimprint (NIL) lithography process or a contact print process. A NIL process may be used to generate the mesh walls by depositing a mesh wall material onto a surface and applying a nanoimprint mold onto the material. The mesh wall material may be cured using thermal curing or using UV light and the nanoimprint mold may be removed from the mesh wall material. The resulting mesh wall may be deposited onto the LED array to create supports for the deposition of a wavelength converting layer 1220. Alternatively, the mesh film may be generated via contact printing photonic columns with, for example, sacrificial PMMA or with UV curable material.

According to an embodiment, a wavelength converting layer may be deposited onto light emitting devices using electrophoretic deposition (EPD). A pixel may include a wavelength converting layer that has a thickness of between 5 and 50 microns. A polymeric toughening additive may be applied to the wavelength converting layer and may reduce cracking or damage to the wavelength converting layer, especially as a result of the thinness of the film. A wavelength converting layer in accordance with embodiments disclosed herein is cerium free and may contain material configured to convert one or more properties of light. The wavelength converting layer may convert a property of light, such as, but not limited to, its wavelength, its phase, or the like. A wavelength converting layer may convert a property of light based on absorption of incoming light by one or more particles in a wavelength converting layer followed by a photon release. A wavelength converting layer may contain applicable luminescent or optically scattering particles such as phosphor grains with or without activation from rare earth ions.

The wavelength converting layer may contain a plurality luminescent or optically scattering particles such as phosphor grains that are 50-500 nm in size. Phosphor grains 50-500 nm in size may be needed as, for example, a pixel that is 30 microns wide may not be able to function efficiently with larger particles such as those that are 1-5 microns in size. Such larger particles may not be efficient as a larger than optimal portion of the light emitted from a light emitting layer may be absorbed by such large particles. Additionally a wavelength converting layer with such large particles may be too large to allow effective operation of a pixel. Accordingly, the convertor film may contain particles that are 50-500 nm in size.

Particles such as phosphor grains that are 50-500 nm in size may traditionally cause degradation in quantum efficiency of the phosphor particles. Such degradation may result in an overall reduced efficiency of a pixel containing particles of such size.

According to the subject matter disclosed herein, Ce(III) doped garnet phosphor grains may be encapsulated in cerium free yttrium aluminum garnet (YAG) shells. The cerium free YAG shells may reduce the non-radiative recombination rate of the wavelength converting layer. Non-radiative recombination is a process where charge carriers recombine without releasing photons. Non-radiative recombination may generate an unintended byproduct such as heat or vibration. Specifically, non-radiative recombination can occur when an electron in the conduction band or on a localized activator excited state recombines with a hole in the valence band or with a localized activator ground state and the excess energy is emitted. Non-radiative recombination may increase the threshold current and may reduce the performance and/or efficiency of a pixel.

By applying cerium free YAG shells to Ce(III) doped garnet phosphor grains and reducing the non-radiative recombination rate, the quantum efficiency of the phosphor particles may be sufficient for optimal operation of a pixel with the wavelength converting layer containing such phosphor particles. As a specific example, the non-radiative recombination rate of the wavelength converting layer may be less than 3 μs⁻¹ and more preferably less than 2 μs⁻¹ (int. QE>88%) as a result of using the cerium free YAG shells. As a comparison, for example, for 100% internal QE luminescence, decay time of YAG:Ce may be ˜70 ns with a radiative recombination rate of ˜14 μs⁻¹. The cerium free YAG shells can be applied by homogeneous precipitation of an yttrium and aluminum containing layer onto the garnet phosphor grains in an aqueous suspension, followed by drying of the coated particles and calcination to obtain Ce(III) doped garnet particles having cerium free YAG shells. The shell thickness may be in the range of 1.5-400 nm, preferably 3-200 nm or even more preferably in the range 10-100 nm.

The phosphor grains in a wavelength converting layer may be homogenous such that all the grains are a specific shape and/or type or may be heterogeneous such that a degree of variation exists between the phosphor grains in the wavelength converting layer. As an example of homogenous phosphor grains, all the phosphor grains in a wavelength converting layer may be between 300 and 320 nm in size. As an example of heterogeneous phosphor grains, one or more phosphor grains in a wavelength converting layer may be between 300 and 400 nm in size and one or more phosphor grains in the wavelength converting layer may be less than 100 nm in size. The phosphor grains may be disk shaped, spherical or may be non-spherical. Additionally, the type of phosphor may be the same or may vary across the wavelength converting layer.

According to an implementation of the disclosed subject matter, one or more types of scattering particles may be provided. The scattering particles may be included in a wavelength converting layer or may be external to the wavelength converting layer such as, for example, in a path of light that is emitted from an active layer. Scattering particles can include silica, titania, zirconia particles, or the like. The size for the scattering particles may range from 10 nm to 1 μm size. The scattering particles may scatter light such that the amount of conversion in a pixel is increased. The scattering particles may have a high density or a low density (e.g., a porous material). Alternatively or in addition, the scattering particles may be a shell with a non-filled core. The scattering particles may reduce the total thickness of a wavelength converting layer by increasing the efficiency of the wavelength conversion. The may also facilitate the application of larger phosphor particles. The scattering particles may also be attached to the phosphor particles by, for example, chemical bonding before the phosphor powders are being deposited onto the light emitting device.

The phosphor grains may be bound by a binder configured to bind the phosphor grains in place. To increase the quantum efficiency of a wavelength converting layer with 50-500 nm phosphor grains, the binder may have a refractive index of 1.65 or greater. The high refractive index may allow light to more efficiently pass through the wavelength converting layer and thus provide a high light extraction. The binder material may be any applicable material such as, but not limited to a glass, a polymer such as acrylate or nitrocellulose, an epoxy, a siloxane, a polysilazane-siloxane hybrid material, a sol-gel material, or the like. The refractive index of the binder may be substantially matched to the refractive index of the cerium free YAG shell to improve the efficiency of the wavelength converting layer.

Quantum dots material may be incorporated within or on the surface of a wavelength converting layer to improve the efficiency of the wavelength converting layer. Quantum dots may luminesce in one or more of the UV, visible and IR (upon excitation with suitable radiation, such as UV radiation). Quantum dots may be made of binary alloys such as cadmium selenide, cadmium sulfide, indium arsenide, and indium phosphide. Alternatively, quantum dots may be made from ternary alloys such as cadmium selenide sulfide. The quantum dots may contain as few as 100 to 100,000 atoms within the quantum dot volume, with a diameter of 10 to 50 atoms. This may correspond to about 2 to 10 nm.

Optical isolation materials may be applied to the sidewall of the wavelength converting layer. Optical isolation materials may include, but are not limited to, distributed Bragg reflector (DBR) layers, reflective material, absorptive material, or the like.

As shown in FIG. 1D, the wavelength converting layer 1220 may at least be the same width as the surface of the light emitting device 1270 to which the layer is attached to. According to an embodiment, the wavelength converting layer 1220 may be wider than the surface of the light emitting device 1270 that the wavelength converting layer is attached to.

Electrophoretic deposition (EPD) may be used to deposit the wavelength converting layer onto a light emitting device. The phosphor grains or nanoparticles may be dispersed in an electron bath such that they are attracted to a charge. A surface of the light emitting device may be charged and the phosphor grains or nanoparticles may be deposited onto the charged surface such that they are attracted specifically to the surface of the light emitting device due to the charge. A binder, as disclosed herein may be deposited onto the phosphor grain or nanoparticles to generate the wavelength converting layer. A curing process may be applied to cure the binder such that the wavelength converting layer maintains its shape.

Using the EPD technique may allow complex patterning of pixels by applying voltage to pixels in a pixel system that need to be patterned with a given wavelength converting layer. A first wavelength converting layer may be deposited on a set of first pixels by applying a voltage to the first set of pixels, and may then be bound and cured. Subsequently, a wavelength converting layer may be deposited on a second set of pixels by applying a voltage to the second set of pixels, and may then be bound and cured.

As shown in FIG. 1H, a wavelength converting layer 320 may be attached to a light emitting device 310. The width w₅ of the wavelength converting layer may be between 5 and 20 microns. An exploded view of phosphor grains 330 is shown. The phosphor grains 330 may be enclosed in a cerium free YAG shell 331 which may reduce the non-radiative recombination effect in the wavelength converting layer 320. Phosphor grains 330 may be dispersed in an electron bath and deposited onto the surface of the light emitting device 310. A voltage may be applied to the surface of the light emitting device 310. The phosphor grains 330 may be attracted to the surface of the light emitting device as a result of the charge from the applied voltage and may disperse on the surface of the light emitting device 310. A binder 340 may be deposited onto the phosphor grains 330 and the surface of the light emitting device 310 and may be cured. The refractive index of the binder may be greater than 1.65 and may be substantially matched to the refractive index of the cerium free YAG shells 331.

FIG. 1I shows an example process 1400 for manufacturing a wavelength converting layer in accordance with the subject matter disclosed herein. As shown, at step 1410, a light emitting surface may be provided. The light emitting surface 1410 may correspond to a light-emitting device 1270 or more specifically to a substrate or semiconductor layer corresponding to light-emitting device 1270. The light emitting surface may be treated (e.g., patterned, chemically treated, etc.) such that it is primed to receive a wavelength converting layer. At step 1420, a wavelength converting layer may be deposited onto the light emitting surface via an electrophoretic deposition process, as disclosed herein. The wavelength converting layer may include a plurality of phosphor grains encapsulated in cerium free YAG shells and may also include a binder as disclosed herein.

FIG. 2A is a top view of an electronics board with an LED array 410 attached to a substrate at the LED device attach region 318 in one embodiment. The electronics board together with the LED array 410 represents an LED system 400A. Additionally, the power module 312 receives a voltage input at Vin 497 and control signals from the connectivity and control module 316 over traces 418B, and provides drive signals to the LED array 410 over traces 418A. The LED array 410 is turned on and off via the drive signals from the power module 312. In the embodiment shown in FIG. 2A, the connectivity and control module 316 receives sensor signals from the sensor module 314 over trace 418C.

FIG. 2B illustrates one embodiment of a two channel integrated LED lighting system with electronic components mounted on two surfaces of a circuit board 499. As shown in FIG. 2B, an LED lighting system 400B includes a first surface 445A having inputs to receive dimmer signals and AC power signals and an AC/DC converter circuit 412 mounted on it. The LED system 400B includes a second surface 445B with the dimmer interface circuit 415, DC-DC converter circuits 440A and 440B, a connectivity and control module 416 (a wireless module in this example) having a microcontroller 472, and an LED array 410 mounted on it. The LED array 410 is driven by two independent channels 411A and 411B. In alternative embodiments, a single channel may be used to provide the drive signals to an LED array, or any number of multiple channels may be used to provide the drive signals to an LED array.

The LED array 410 may include two groups of LED devices. In an example embodiment, the LED devices of group A are electrically coupled to a first channel 411A and the LED devices of group B are electrically coupled to a second channel 411B. Each of the two DC-DC converters 440A and 440B may provide a respective drive current via single channels 411A and 411B, respectively, for driving a respective group of LEDs A and B in the LED array 410. The LEDs in one of the groups of LEDs may be configured to emit light having a different color point than the LEDs in the second group of LEDs. Control of the composite color point of light emitted by the LED array 410 may be tuned within a range by controlling the current and/or duty cycle applied by the individual DC/DC converter circuits 440A and 440B via a single channel 411A and 411B, respectively. Although the embodiment shown in FIG. 2B does not include a sensor module (as described in FIG. 2A), an alternative embodiment may include a sensor module.

The illustrated LED lighting system 400B is an integrated system in which the LED array 410 and the circuitry for operating the LED array 410 are provided on a single electronics board. Connections between modules on the same surface of the circuit board 499 may be electrically coupled for exchanging, for example, voltages, currents, and control signals between modules, by surface or sub-surface interconnections, such as traces 431, 432, 433, 434 and 435 or metallizations (not shown). Connections between modules on opposite surfaces of the circuit board 499 may be electrically coupled by through board interconnections, such as vias and metallizations (not shown).

According to embodiments, LED systems may be provided where an LED array is on a separate electronics board from the driver and control circuitry. According to other embodiments, a LED system may have the LED array together with some of the electronics on an electronics board separate from the driver circuit. For example, an LED system may include a power conversion module and an LED module located on a separate electronics board than the LED arrays.

According to embodiments, an LED system may include a multi-channel LED driver circuit. For example, an LED module may include embedded LED calibration and setting data and, for example, three groups of LEDs. One of ordinary skill in the art will recognize that any number of groups of LEDs may be used consistent with one or more applications. Individual LEDs within each group may be arranged in series or in parallel and the light having different color points may be provided. For example, warm white light may be provided by a first group of LEDs, a cool white light may be provided by a second group of LEDs, and a neutral white light may be provided by a third group.

FIG. 2C shows an example vehicle headlamp system 300 including a vehicle power 302 including a data bus 304. A sensor module 307 may be connected to the data bus 304 to provide data related to environment conditions (e.g. ambient light conditions, temperature, time, rain, fog, etc.), vehicle condition (parked, in-motion, speed, direction), presence/position of other vehicles, pedestrians, objects, or the like. The sensor module 307 may be similar to or the same as the sensor module 314 of FIG. 2A. AC/DC Converter 305 may be connected to the vehicle power 302.

The power module 312 (AC/DC converter) of FIG. 2C may be the same as or similar to the AC/DC converter 412 of FIG. 2B and may receive AC power from the vehicle power 302. It may convert the AC power to DC power as described in FIG. 2B for AC-DC converter 412. The vehicle head lamp system 300 may include an active head lamp 331 which receives one or more inputs provided by or based on the AC/DC converter 305, connectivity and control module 306, and/or sensor module 307. As an example, the sensor module 307 may detect the presence of a pedestrian such that the pedestrian is not well lit, which may reduce the likelihood that a driver sees the pedestrian. Based on such sensor input, the connectivity and control module 306 may output data to the active head lamp 331 using power provided from the AC/DC converter 305 such that the output data activates a subset of LEDs in an LED array contained within active head lamp 331. The subset of LEDs in the LED array, when activated, may emit light in the direction where the sensor module 307 sensed the presence of the pedestrian. These subset of LEDs may be deactivated or their light beam direction may otherwise be modified after the sensor module 207 provides updated data confirming that the pedestrian is no longer in a path of the vehicle that includes vehicle head lamp system.

FIG. 3 shows an example system 550 which includes an application platform 560, LED systems 552 and 556, and optics 554 and 558. The LED System 552 produces light beams 561 shown between arrows 561a and 561b. The LED System 556 may produce light beams 562 between arrows 562a and 562b. In the embodiment shown in FIG. 3, the light emitted from LED System 552 passes through secondary optics 554, and the light emitted from the LED System 556 passes through secondary optics 558. In alternative embodiments, the light beams 561 and 562 do not pass through any secondary optics. The secondary optics may be or may include one or more light guides. The one or more light guides may be edge lit or may have an interior opening that defines an interior edge of the light guide. LED systems 552 and/or 556 may be inserted in the interior openings of the one or more light guides such that they inject light into the interior edge (interior opening light guide) or exterior edge (edge lit light guide) of the one or more light guides. LEDs in LED systems 552 and/or 556 may be arranged around the circumference of a base that is part of the light guide. According to an implementation, the base may be thermally conductive. According to an implementation, the base may be coupled to a heat-dissipating element that is disposed over the light guide. The heat-dissipating element may be arranged to receive heat generated by the LEDs via the thermally conductive base and dissipate the received heat. The one or more light guides may allow light emitted by LED systems 552 and 556 to be shaped in a desired manner such as, for example, with a gradient, a chamfered distribution, a narrow distribution, a wide distribution, an angular distribution, or the like.

In example embodiments, the system 550 may be a mobile phone of a camera flash system, indoor residential or commercial lighting, outdoor light such as street lighting, an automobile, a medical device, AR/VR devices, and robotic devices. The LED System 400A shown in FIG. 2A and vehicle head lamp system 300 shown in FIG. 2C illustrate LED systems 552 and 556 in example embodiments.

The application platform 560 may provide power to the LED systems 552 and/or 556 via a power bus via line 565 or other applicable input, as discussed herein. Further, application platform 560 may provide input signals via line 565 for the operation of the LED system 552 and LED system 556, which input may be based on a user input/preference, a sensed reading, a pre-programmed or autonomously determined output, or the like. One or more sensors may be internal or external to the housing of the application platform 560. Alternatively or in addition, as shown in the LED system 400 of FIG. 2A, each LED System 552 and 556 may include its own sensor module, connectivity and control module, power module, and/or LED devices.

In embodiments, application platform 560 sensors and/or LED system 552 and/or 556 sensors may collect data such as visual data (e.g., LIDAR data, IR data, data collected via a camera, etc.), audio data, distance based data, movement data, environmental data, or the like or a combination thereof. The data may be related a physical item or entity such as an object, an individual, a vehicle, etc. For example, sensing equipment may collect object proximity data for an ADAS/AV based application, which may prioritize the detection and subsequent action based on the detection of a physical item or entity. The data may be collected based on emitting an optical signal by, for example, LED system 552 and/or 556, such as an IR signal and collecting data based on the emitted optical signal. The data may be collected by a different component than the component that emits the optical signal for the data collection. Continuing the example, sensing equipment may be located on an automobile and may emit a beam using a vertical-cavity surface-emitting laser (VCSEL). The one or more sensors may sense a response to the emitted beam or any other applicable input.

In example embodiment, application platform 560 may represent an automobile and LED system 552 and LED system 556 may represent automobile headlights. In various embodiments, the system 550 may represent an automobile with steerable light beams where LEDs may be selectively activated to provide steerable light. For example, an array of LEDs may be used to define or project a shape or pattern or illuminate only selected sections of a roadway. In an example embodiment, Infrared cameras or detector pixels within LED systems 552 and/or 556 may be sensors (e.g., similar to sensors module 314 of FIG. 2A and 307 of FIG. 2C) that identify portions of a scene (roadway, pedestrian crossing, etc.) that require illumination.

Although features and elements are described above in particular combinations, one of ordinary skill in the art will appreciate that each feature or element can be used alone or in any combination with the other features and elements. In addition, the methods described herein may be implemented in a computer program, software, or firmware incorporated in a computer-readable medium for execution by a computer or processor. Examples of computer-readable media include electronic signals (transmitted over wired or wireless connections) and computer-readable storage media. Examples of computer-readable storage media include, but are not limited to, a read only memory (ROM), a random access memory (RAM), a register, cache memory, semiconductor memory devices, magnetic media such as internal hard disks and removable disks, magneto-optical media, and optical media such as CD-ROM disks, and digital versatile disks (DVDs).

Claims

1. A device comprising:

a light emitting layer; and

a wavelength converting layer having a thickness of 5-20 microns over the light emitting layer, the wavelength converting layer comprising: a plurality of phosphor grains 50-500 nm in size and encapsulated in cerium free YAG shells; and a binder material binding the plurality of phosphor grains.

2. The device of claim 1, wherein the binder material has a RI of greater than 1.65.

3. The device of claim 1, wherein a non-radiative recombination rate of the wavelength converting layer is less than 3 μs−1.

4. The device of claim 1, wherein the wavelength converting layer formed by depositing the plurality of phosphor grains onto the wavelength converting layer via an electrophoretic process.

5. The device of claim 1, wherein a first phosphor grain of the plurality of phosphor grains is a first phosphor type and a second phosphor grain of the plurality of phosphor grains is a second phosphor type.

6. The device of claim 5, wherein the first phosphor grain is 300-400 nm in size and the second phosphor grain is less than 100 nm in size.

7. The device of claim 1, wherein the refractive index of the cerium free YAG shell is substantially matched to the refractive index of the binder.

8. The device of claim 1, wherein the wavelength converting layer further comprises a polymeric toughening additive.

9. The device of claim 1, further comprising an optical isolation material attached to a sidewall of the wavelength converting layer, the optical isolation material selected from one of a DBR, a reflective material and an absorptive material.

10. The device of claim 1, further comprising quantum dot material in contact with the wavelength converting layer.

11. The device of claim 1, wherein the surface area of a first side of the wavelength converting layer that is attached to the light emitting surface is larger than the surface area of the light emitting surface.

12. The device of claim 1, further comprising scattering particles.

13. A wavelength converting layer comprising:

a plurality of phosphor grains 50-500 nm in size and encapsulated in cerium free YAG shells; and

a binder material binding the plurality of phosphor grains, the wavelength converting layer having a thickness of 5-20 microns attached to the light emitting surface.

14. The wavelength converting layer of claim 13, wherein the binder material has a RI of greater than 1.65.

15. The wavelength converting layer of claim 13, wherein a first phosphor grain of the plurality of phosphor grains is a first phosphor type and a second phosphor grain of the plurality of phosphor grains is a second phosphor type.

16. The wavelength converting layer of claim 13, wherein the wavelength converting layer further comprises a polymeric toughening additive.

17. A method comprising:

providing a light emitting surface;

depositing, via electrophoretic deposition, a wavelength converting layer over the light emitting surface, the wavelength converting layer comprising: a plurality of phosphor grains 50-500 nm in size and encapsulated in cerium free YAG shells; and a binder material binding the plurality of phosphor grains, the wavelength converting layer having a thickness of 5-20 microns attached to the light emitting surface.

18. The method of claim 17, wherein the binder material has a RI of greater than 1.65.

19. The method of claim 17, wherein a first phosphor grain of the plurality of phosphor grains is a first phosphor type and a second phosphor grain of the plurality of phosphor grains is a second phosphor type.

20. The method of claim 17, wherein the wavelength converting layer further comprises a polymeric toughening additive.