WO2005101909A1 - Light-emitting devices having multiple encapsulation layers with at least one of the encapsulation layers including nanoparticles and methods of forming the same - Google Patents

Light-emitting devices having multiple encapsulation layers with at least one of the encapsulation layers including nanoparticles and methods of forming the same Download PDF

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Publication number
WO2005101909A1
WO2005101909A1 PCT/US2005/011592 US2005011592W WO2005101909A1 WO 2005101909 A1 WO2005101909 A1 WO 2005101909A1 US 2005011592 W US2005011592 W US 2005011592W WO 2005101909 A1 WO2005101909 A1 WO 2005101909A1
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WO
WIPO (PCT)
Prior art keywords
encapsulation layer
light
nanoparticles
matrix material
emitting device
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2005/011592
Other languages
English (en)
French (fr)
Inventor
Gerald H. Negley
Eric Tarsa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Wolfspeed Inc
Original Assignee
Cree Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cree Inc filed Critical Cree Inc
Priority to KR1020117020217A priority Critical patent/KR101225252B1/ko
Priority to JP2007507454A priority patent/JP5376801B2/ja
Priority to KR1020067020679A priority patent/KR101138540B1/ko
Priority to DE602005011119T priority patent/DE602005011119D1/de
Priority to EP05734066A priority patent/EP1741315B1/en
Publication of WO2005101909A1 publication Critical patent/WO2005101909A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/852—Encapsulations
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00—Electroluminescent light sources
    • H05B33/02—Details
    • H05B33/04—Sealing arrangements, e.g. against humidity
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/852—Encapsulations
    • H10H20/853—Encapsulations characterised by their shape
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/852—Encapsulations
    • H10H20/854—Encapsulations characterised by their material, e.g. epoxy or silicone resins

Definitions

  • the present invention relates generally to microelectronic devices and fabrication methods therefor, and, more particularly, to light-emitting devices and fabrication methods therefor.
  • LEDs Light-emitting diodes
  • a light-emitting diode generally includes an active region on a microelectronic substrate.
  • the microelectronic substrate may comprise, for example, gallium arsenide, gallium phosphide, alloys thereof, silicon carbide, and/or sapphire.
  • a light-emitting device includes an active region that is configured to emit light responsive to a voltage applied thereto.
  • a first encapsulation layer at least partially encapsulates the active region and includes a matrix material and nanoparticles, which modify at least one physical property of the first encapsulation layer.
  • a second encapsulation layer at least partially encapsulates the first encapsulation layer.
  • the matrix material comprises silicone, a silicone compound, an optical gel, epoxy resin, glass, sol-gel, aerogel, and/or an optically stable polymer.
  • the first encapsulation layer is substantially transparent.
  • the nanoparticles comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the at least one physical property comprises index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability.
  • the matrix material is a first matrix material, and the nanoparticles are first nanoparticles.
  • the second encapsulation layer comprises a second matrix material and second nanoparticles that modify at least one physical property of the second encapsulation layer.
  • the second matrix material comprises silicone, a silicone compound, an optical gel, epoxy resin, glass, sol-gel, aerogel, and/or an optically stable polymer.
  • the second encapsulation layer is substantially transparent.
  • the second nanoparticles comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the at least one physical property of the second encapsulation layer comprises index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability.
  • an outer surface of the first encapsulation layer, opposite the active region may be shaped so that light rays from the active region are not incident on the first encapsulation layer at an angle that is greater than a critical angle.
  • FIGS. 1A - IB are cross-sectional diagrams that illustrate light-emitting devices and fabrication methods therefor, in accordance with some embodiments of the present invention
  • FIGS. 2A - 2C are cross-sectional diagrams that illustrate light-emitting devices and fabrication methods therefor, in accordance with additional embodiments of the present invention
  • FIGS. 3A - 3D are cross-sectional diagrams that illustrate light-emitting devices and fabrication methods therefor, in accordance with additional embodiments of the present invention.
  • Examples of light-emitting devices that may be used in embodiments of the present invention include, but are not limited to, LEDs and/or laser diodes, such as devices manufactured and sold by Cree, Inc. of Durham, North Carolina.
  • the present invention may be suitable for use with LEDs and/or lasers as described in United States Patent Nos.
  • the LEDs and/or lasers may be configured to operate in a "flip-chip" configuration such that light emission occurs through the substrate.
  • the substrate may be patterned so as to enhance light output of the devices as is described, for example, in United States Patent Application Serial No. 10/057,821, filed January 25, 2002 entitled “LIGHT EMITTING DIODES INCLUDING SUBSTRATE MODIFICATIONS FOR LIGHT EXTRACTION AND MANUFACTURING METHODS THEREFOR” the disclosure of which is incorporated herein by reference as if set forth fully herein.
  • FIGS. 1A - IB are cross-sectional diagrams that illustrate light-emitting devices and fabrication methods therefor, in accordance with some embodiments of the present invention. Referring now to FIG.
  • a light-emitting device 10 in accordance with some embodiments of the present invention, includes an LED, which includes an anode terminal 12, an active region 13, such as a diode region, and a cathode terminal 14, which are electrically coupled to one another.
  • the active region 13 is configured to emit light responsive to a voltage applied thereto via, for example, the anode and cathode terminals 12 and 14.
  • the light-emitting device 10 further includes a first encapsulation layer 16, which includes, for example, a matrix material and nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the first encapsulation layer 16.
  • the first encapsulation layer 16 at least partially encapsulates the active region in accordance with some embodiments of the present invention and may be substantially transparent.
  • the matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol- gel, aerogel, and/or an optically stable polymer.
  • the silicone gel is generally optically stable when exposed to relatively high flux, short wavelength light (e.g., on the order of 525 nm).
  • the nanoparticles in the first encapsulation layer 16 may comprise TiO , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the first encapsulation layer 16 may comprise a silicone gel having TiO 2 nanoparticles contained therein.
  • the TiO 2 nanoparticles contained in the silicone gel may increase the index of refraction of the first encapsulation layer 16 to allow the index of refraction of the first encapsulation layer 16 to more closely match the index of refraction of the active region 13 thereby improving light extraction from the active region 13.
  • an outer surface of the first encapsulation layer 16, opposite the active region 13, may be shaped so that light rays from the active region 13 are not incident on the first encapsulation layer 16 at an angle that is greater than the critical angle, in accordance with some embodiments of the present invention.
  • the first encapsulation layer 16 is at least partially encapsulated with a second encapsulation layer 18, which may comprise a second matrix material and second nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the second encapsulation layer 18.
  • the second encapsulation layer 18 and may be substantially transparent.
  • the second matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol-gel, aerogel, and/or an optically stable polymer.
  • the second nanoparticles may comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the second encapsulation layer 18 may include epoxy, plastic, and/or glass to add rigidity to the packaging of the light-emitting device 10.
  • a third encapsulation layer 19, which may be substantially transparent, may be used to at least partially encapsulate the second encapsulation layer 18 in accordance with some embodiments of the present invention.
  • the third encapsulation layer 19 may include a thermally conductive material.
  • the first, second, and third encapsulation layers 16, 18, and 19 may be formed using a casting process.
  • FIGS. 2A - 2C are cross-sectional diagrams that illustrate light-emitting devices and fabrication methods therefor, in accordance with further embodiments of the present invention.
  • a light-emitting device 20 in accordance with some embodiments of the present invention, includes an LED, which includes an anode terminal 22, an active region 23, such as a diode region, and a cathode terminal 24, which are electrically coupled to one another.
  • the active region 23 is configured to emit light responsive to a voltage applied thereto via, for example, the anode and cathode terminals 22 and 24.
  • the light-emitting device 20 further includes a first encapsulation layer 26, which includes, for example, a matrix material and nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the first encapsulation layer 26.
  • the first encapsulation layer 26 at least partially encapsulates the active region in accordance with some embodiments of the present invention and may be substantially transparent.
  • the matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol- gel, aerogel, and/or an optically stable polymer.
  • the nanoparticles in the first encapsulation layer 26 may comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the first encapsulation layer 26 may comprise silicone gel, epoxy, and/or a polymer having TiO 2 nanoparticles contained therein.
  • the TiO 2 nanoparticles contained in the matrix material may increase the index of refraction of the first encapsulation layer 26 to allow the index of refraction of the first encapsulation layer 26 to more closely match the index of refraction of the active region 23 thereby improving light extraction from the active region 23.
  • an outer surface of the first encapsulation layer 26, opposite the active region 23, may be shaped so that light rays from the active region 23 are not incident on the first encapsulation layer 26 at an angle that is greater than the critical angle, in accordance with some embodiments of the present invention.
  • the first encapsulation layer 26 may further include phosphor particles, to fabricate, for example, a white LED lamp, in accordance with some embodiments of the present invention.
  • the first encapsulation layer 26 may be formed using a casting or dispensing process. Referring now to FIG.
  • the light-emitting device 20 further comprises a second encapsulation layer 27 that at least partially encapsulates the first encapsulation layer 26 and may be substantially transparent.
  • the second encapsulation layer 27 may comprise a second matrix material and second nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the second encapsulation layer 27.
  • the second matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol-gel, aerogel, and/or an optically stable polymer.
  • the second nanoparticles may comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the second encapsulation layer 27 may comprise silicone gel.
  • the second encapsulation layer 27 is at least partially encapsulated with a third encapsulation layer 28, which may be substantially transparent and may comprise a third matrix material and third nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the third encapsulation layer 28.
  • the third matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol-gel, aerogel, and/or an optically stable polymer.
  • the third nanoparticles may comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the third encapsulation layer 28 may include epoxy, plastic, and/or glass to add rigidity to the packaging of the light-emitting device 20.
  • a fourth encapsulation layer 29 may be used to at least partially encapsulate the third encapsulation layer 28 in accordance with some embodiments of the present invention.
  • the fourth encapsulation layer 29 may include a thermally conductive material and may be substantially transparent.
  • the second, third, and fourth encapsulation layers 27, 28, and 29 may be formed using a casting process.
  • FIGS. 3A - 3D are cross-sectional diagrams that illustrate light-emitting devices and fabrication methods therefor, in accordance with some other embodiments of the present invention.
  • a light-emitting device 30, in accordance with some embodiments of the present invention includes an LED, which includes an anode terminal 32, an active region 33, such as a diode region, and a cathode terminal 34, which are electrically coupled to one another.
  • the active region 33 is configured to emit light responsive to a voltage applied thereto via, for example, the anode and cathode terminals 32 and 34.
  • the light-emitting device 30 further includes a first encapsulation layer 35, which includes, for example, a matrix material and nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the first encapsulation layer 35.
  • the first encapsulation layer 35 at least partially encapsulates the active region and may be substantially transparent in accordance with some embodiments of the present invention.
  • the matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol- gel, aerogel, and/or an optically stable polymer.
  • the nanoparticles in the first encapsulation layer 35 may comprise TiO , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the first encapsulation layer 35 may comprise silicone gel, epoxy, and/or a polymer having TiO 2 nanoparticles contained therein.
  • the TiO 2 nanoparticles contained in the matrix material may increase the index of refraction of the first encapsulation layer 36 to allow the index of refraction of the first encapsulation layer 35 to more closely match the index of refraction of the active region 35 thereby improving light extraction from the active region 33.
  • an outer surface of the first encapsulation layer 35, opposite the active region 33 may be shaped so that light rays from the active region 33 are not incident on the first encapsulation layer 35 at an angle that is greater than the critical angle, in accordance with some embodiments of the present invention. Referring now to FIG.
  • the light-emitting device 30 further comprises a second encapsulation layer 36 that at least partially encapsulates the first encapsulation layer 35 and may be substantially transparent.
  • the second encapsulation layer 36 may comprise a second matrix material and second nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the second encapsulation layer 36.
  • the second matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol-gel, aerogel, and/or an optically stable polymer.
  • the second nanoparticles may comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the second encapsulation layer 36 may comprise silicone gel, epoxy, and/or a polymer having phosphor particles contained therein to fabricate, for example, a white LED lamp, in accordance with some embodiments of the present invention.
  • the second encapsulation layer 36 may further include TiO 2 nanoparticles in accordance with some embodiments of the present invention.
  • increased light output may be obtained from the light-emitting device.
  • the first and second encapsulation layers 35 and 36 may be formed using a casting or dispensing process.
  • the light-emitting device 30 further comprises a third encapsulation layer 37, that at least partially encapsulates the second encapsulation layer 36 and may be substantially transparent.
  • the third encapsulation layer 37 may comprise a third matrix material and third nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the third encapsulation layer 37.
  • the third matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol-gel, aerogel, and/or an optically stable polymer.
  • the third nanoparticles may comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the third encapsulation layer 37 may comprise silicone gel.
  • the third encapsulation layer 37 is at least partially encapsulated with a fourth encapsulation layer 38, which may be substantially transparent and may comprise a fourth matrix material and fourth nanoparticles that modify at least one physical property, such as, for example, index of refraction, thermal conductivity, mechanical strength, abrasion resistance, and/or optical stability of the fourth encapsulation layer 38.
  • the fourth matrix material may comprise silicone, a silicone compound, an optical gel, epoxy resin, glass, sol-gel, aerogel, and/or an optically stable polymer.
  • the fourth nanoparticles may comprise TiO 2 , diamond, silicon carbide, scattering particles, fillers, phosphors, and/or light conversion materials.
  • the fourth encapsulation layer 38 may include epoxy, plastic, and/or glass to add rigidity to the packaging of the light-emitting device 30.
  • a fifth encapsulation layer 39 may be used to at least partially encapsulate the fourth encapsulation layer 38 in accordance with some embodiments of the present invention.
  • the fifth encapsulation layer 39 may include a thermally conductive material and may be substantially transparent.
  • the third, fourth, and fifth encapsulation layers 37, 38, and 39 may be formed using a casting process.
  • embodiments of the invention may comprise a sequence of multiple (two or more) encapsulation layers, each either fully or partially encapsulating the previous layers or light-emitting device.
  • Each encapsulation layer may comprise one of a variety of matrix, nanoparticle, additive/filler materials as described above, and each layer may serve a specific complimentary function to improve the performance of the resulting package. It is generally desirable that the encapsulation layers do not substantially absorb light from the light-emitting device.
  • the interface between the encapsulation layers may be designed to enhance the optical and/or chemical properties. Compatibility of chemical and other physical properties, such as chemical reactions, adhesion, thermal expansion, etc. may place constraints upon the geometry and/or the configuration of the interface between various encapsulation layers.

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PCT/US2005/011592 2004-04-06 2005-04-05 Light-emitting devices having multiple encapsulation layers with at least one of the encapsulation layers including nanoparticles and methods of forming the same Ceased WO2005101909A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
KR1020117020217A KR101225252B1 (ko) 2004-04-06 2005-04-05 다중 봉지층으로서 적어도 하나의 봉지층이 나노입자를 포함하는 다중 봉지층을 구비하는 발광 소자 및 그의 형성 방법
JP2007507454A JP5376801B2 (ja) 2004-04-06 2005-04-05 少なくとも一つのカプセル化層がナノ粒子群を含む複数のカプセル化層を有する発光素子およびその形成方法
KR1020067020679A KR101138540B1 (ko) 2004-04-06 2005-04-05 다중 봉지층으로서 적어도 하나의 봉지층이 나노입자를포함하는 다중 봉지층을 구비하는 발광 소자 및 그의 형성방법
DE602005011119T DE602005011119D1 (de) 2004-04-06 2005-04-05 Lichtemittierende bauelemente mit mehreren verkapselungsschichten, wobei mindestens eine der verkapselungsschichten nanopartikel enthält, und herstellungsverfahren dafür
EP05734066A EP1741315B1 (en) 2004-04-06 2005-04-05 Light-emitting devices having multiple encapsulation layers with at least one of the encapsulation layers including nanoparticles and methods of forming the same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/818,912 US7868343B2 (en) 2004-04-06 2004-04-06 Light-emitting devices having multiple encapsulation layers with at least one of the encapsulation layers including nanoparticles and methods of forming the same
US10/818,912 2004-04-06

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WO2005101909A1 true WO2005101909A1 (en) 2005-10-27

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PCT/US2005/011592 Ceased WO2005101909A1 (en) 2004-04-06 2005-04-05 Light-emitting devices having multiple encapsulation layers with at least one of the encapsulation layers including nanoparticles and methods of forming the same

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US (2) US7868343B2 (https=)
EP (1) EP1741315B1 (https=)
JP (2) JP5376801B2 (https=)
KR (2) KR101138540B1 (https=)
AT (1) ATE415072T1 (https=)
DE (1) DE602005011119D1 (https=)
TW (1) TWI364115B (https=)
WO (1) WO2005101909A1 (https=)

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