Philips Lumileds Lighting Company LLC

Koninklijke Philips Electronics N.v.

Tze-Sen Lim

Paul Scott Martin

Gerd O Mueller

Grigoriy Basin

Regina B Mueller-Mach

Robert Scott West

Stefan Eberle

Overmolded lenses and certain fabrication techniques are described for LED structures. In one embodiment, thin YAG phosphor plates are formed and affixed over blue LEDs mounted on a submount wafer. A clear lens is then molded over each LED structure during a single molding process. The LEDs are then separated from the wafer. The molded lens may include red phosphor to generate a warmer white light. In another embodiment, the phosphor plates are first temporarily mounted on a backplate, and a lens containing a red phosphor is molded over the phosphor plates. The plates with overmolded lenses are removed from the backplate and affixed to the top of an energizing LED. A clear lens is then molded over each LED structure. The shape of the molded phosphor-loaded lenses may be designed to improve the color vs. angle uniformity. Multiple dies may be encapsulated by a single lens. In another embodiment, a prefabricated collimating lens is glued to the flat top of an overmolded lens.

LED with phosphor tile and overmolded phosphor in lens

Growing community of inventors

Bayan Lepas, Malaysia

Tze-Sen Lim