Light emitting diode die with at least one phosphor layer and method for forming the same

Abstract

The present application discloses a light emitting diode die with at least one phosphor layer, comprising a substrate having a first surface and a second surface opposing to the first surface; a light-emitting structure being formed on the first surface and emitting a primary light with a specific wavelength while being driven by a voltage wherein the primary light is capable of passing through the substrate; and, at least one phosphor layer with plate-shaped structure formed on the second surface, wherein at least one phosphor layer comprises at least one type of organic material and at least one type of phosphor substance that absorbs and converts part of the primary light to thereby emit at least a secondary light with a different wavelength from the specific wavelength. In addition, the present invention discloses methods for forming a light emitting diode die with at least one phosphor layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows the schematic structure of a light emitting diode die having a phosphor layer according to the first embodiment of the present invention;

FIG. 1B shows the schematic structure of phosphor substance unevenly dispersed in the phosphor layer according to the first embodiment of the present invention;

FIG. 1C shows the schematic structure of phosphor substance unevenly dispersed in the phosphor layer according to the first embodiment of the present invention;

FIG. 1D shows the schematic structure of phosphor substance unevenly dispersed in the phosphor layer according to the first embodiment of the present invention;

FIG. 1E shows the schematic structure of phosphor substance unevenly dispersed in the phosphor layer according to the first embodiment of the present invention;

FIG. 1F shows the schematic structure of a light emitting diode die having a protection layer according to the first embodiment of the present invention;

FIG. 1G shows the schematic structure of a light emitting diode die having a ultraviolet light blocking layer according to the first embodiment of the present invention;

FIG. 1H shows the schematic structure of a light emitting diode die having two phosphor layers with different refractive indexes according to the first embodiment of the present invention;

FIG. 2 shows the schematic structure of a light emitting diode die having a plurality of phosphor layers according to the second embodiment of the present invention;

FIG. 2 shows the flow chart for manufacturing a light emitting diode die with at least one phosphor layer according to the second embodiment of the present invention;

FIG. 3A shows the flow chart for manufacturing a light emitting diode die with at least one phosphor layer according to the third embodiment of the present invention;

FIG. 3B shows the flow chart for unevenly dispersing phosphor substance in the phosphor layer according to the third embodiment of the present invention;

FIG. 3C shows the flow chart for unevenly dispersing phosphor substance in the phosphor layer according to the third embodiment of the present invention;

FIG. 3D shows the flow chart for unevenly dispersing phosphor substance in the phosphor layer according to the third embodiment of the present invention;

FIG. 4 shows the flow chart for manufacturing a light emitting diode die with at least one phosphor layer according to the fourth embodiment of the present invention.

Claims

1. A light emitting diode die with at least one phosphor layer, comprising: a substrate having a first surface and a second surface opposing to said first surface;a light-emitting structure being formed on said first surface and configured to emit a primary light with a first wavelength when driven by a voltage, wherein the substrate is configured to transmit the primary light therethrough; and,at least one phosphor layer with a plate-shaped structure formed on said second surface, wherein said at least one phosphor layer comprises at least one type of organic material and at least one type of phosphor particles distributed in a matrix of the organic material and configured to absorb and convert at least a part of the primary light to thereby emit at least a secondary light with a different wavelength from the first wavelength.

2. The light emitting diode die according to claim 1, wherein said phosphor particles are unevenly dispersed in said phosphor layer, and the dispersion density of the phosphor particles increases along a specific direction that parallels the direction of said phosphor layer.

3. The light emitting diode die according to claim 1, wherein said phosphor particles are unevenly dispersed in said phosphor layer, and the dispersion density of the phosphor particles increases along a radial direction from the center of said phosphor layer, as viewed from top of said phosphor layer.

4. The light emitting diode die according to claim 1, wherein said phosphor particles are unevenly dispersed in said phosphor layer, and the dispersion density of the phosphor particles decreases along a radial direction from the center of said phosphor layer, as viewed from top of said phosphor layer.

5. The light emitting diode die according to claim 1, wherein said phosphor particles are unevenly dispersed in said phosphor layer, and the dispersion density of the phosphor particles has an undulating density distribution radially spreading out from the center of said phosphor layer, as viewed from top of said phosphor layer.

6. The light emitting diode die according to claim 1, wherein said organic material comprises small molecules, oligomers, or polymers.

7. The light emitting diode die according to claim 6, wherein said organic material comprises a polymer and the glass transition temperature of the polymer is equal to or greater than 150° C.

8. The light emitting diode die according to claim 6, wherein said organic material comprises a polymer and the polymer comprises epoxy, polyether-polysulfone (PES), polyarylene sulfide (PAS), polybenzimidazoles (PBI), polyacrylate, polyamide (PA), polyimide (PI), polyether-polyimide (PEI), polyarylate (PAR), cyclic olefin copolymer (COC), polycarbonate (PC), or their copolymers.

9. The light emitting diode die according to claim 6, wherein said phosphor layer is a thick film and has a thickness equal to or greater than 1 μm.

10. The light emitting diode die according to claim 1, wherein said phosphor layer is formed by a method comprising coating, printing, screen printing, spraying, impressing or inkjet printing.

11. The light emitting diode die according to claim 1, further comprising a protection layer formed on said at least one phosphor layer.

12. The light emitting diode die according to claim 1, further comprising an ultraviolet light filtering layer formed on said at least one phosphor layer to impede ultraviolet light from leaking out.

13. The light emitting diode die according to claim 12, wherein said ultraviolet light blocking layer comprises a secondary multilayer structure.

14. The light emitting diode die according to claim 13, wherein said secondary multilayer structure comprises a Bragg reflector.

15. The light emitting diode die according to claim 1, wherein said at least one phosphor layer comprises a plurality of phosphor layers.

16. The light emitting diode die according to claim 15, wherein the refractive index of each phosphor layer of said phosphor layers decreases with the increase of the distance between each phosphor layer and said light-emitting structure.

17. A method for forming a light emitting diode die with at least one phosphor layer, comprising: providing a wafer having a first surface and a second surface opposing to said first surface;forming a light-emitting structure on said first surface of said wafer;blending at least one type of phosphor substance with at least one type of organic material to disperse said phosphor substance into said organic material so as to form an intermediate solution;performing a depositing process to deposit said intermediate solution onto said second surface of said wafer;performing a curing process to cure said intermediate solution on said second surface to form a phosphor layer; andperforming a wafer dicing process to form a plurality of light emitting diode dies with a phosphor layer.

18. The method according to claim 17, wherein said organic material comprises molecules, oligomers, or polymers.

19. The method according to claim 17, wherein said organic material is polymer and the glass transition temperature of the polymer is equal to or more than 150° C.

20. The method according to claim 17, wherein said organic material is polymer and the polymer comprises epoxy, polyether-polysulfone (PES), polyarylene sulfide (PAS), polybenzimidazoles (PBI), polyacrylate, polyamide (PA), polyimide (PI), polyether-polyimide (PEI), polyarylate (PAR), cyclic olefin copolymer (COC), polycarbonate (PC), or their copolymers.

21. The method according to claim 17, wherein said depositing process comprises coating, printing, screen printing, spraying, impressing or inkjet printing.

22. The method according to claim 17, wherein said curing process comprises a cross-linking process.

23. A method for forming a light emitting diode die with at least one phosphor layer, comprising: providing a wafer having a first surface and a second surface opposing to said first surface;forming a light-emitting structure on said first surface of said wafer;performing a depositing process to deposit at least one type of organic material onto said second surface of said wafer;performing a spraying process to spray at least one type of phosphor substance onto said organic material;performing a curing process to cure said organic material on said second surface to fix the relative position between said phosphor substance and said organic material so as to form a phosphor layer; andperforming a wafer dicing process to form a plurality of light emitting diode dies with a phosphor layer.

24. The method according to claim 23, wherein said phosphor particles are unevenly dispersed in said phosphor layer, and the dispersion density of the phosphor particles increases along a specific direction that parallels the direction of said phosphor layer.

25. The method according to claim 23, wherein said phosphor particles are unevenly dispersed in said phosphor layer, and the dispersion density of the phosphor particles increases along a radial direction from the center of said phosphor layer, as viewed from top of said phosphor layer.

26. The method according to claim 23, wherein said phosphor particles are unevenly dispersed in said phosphor layer, and the dispersion density of the phosphor particles decreases along a radial direction from the center of said phosphor layer, as viewed from top of said phosphor layer.

27. The method according to claim 23, wherein said phosphor particles are unevenly dispersed in said phosphor layer, and the dispersion density of the phosphor particles has an undulating distribution radially spreading out from the center of said phosphor layer, as viewed from top of said phosphor layer.

28. A method for forming a light emitting diode die with at least one phosphor layer, comprising: providing a wafer having a first surface and a second surface opposing to said first surface;forming a light-emitting structure on said first surface of said wafer;performing a first depositing process to deposit at least one type of first organic material onto said second surface of said wafer;performing a spraying process to spray at least one type of phosphor substance onto said first organic material;performing a first curing process to cure said first organic material on said second surface to fix the relative position between said phosphor substance and said first organic material so as to form a first phosphor layer;performing a second depositing process to deposit at least one type of second organic material onto said first phosphor layer;performing a second curing process to cure said second organic material on said first phosphor layer so as to form a second phosphor layer; and,performing a wafer dicing process to form a plurality of light emitting diode dies with phosphor layers.

29. The method according to claim 28, wherein said phosphor particles are unevenly dispersed on said first phosphor layer, and the dispersion density of the phosphor particles increases along a specific direction that parallels the direction of said phosphor layer.

30. The method according to claim 28, wherein said phosphor particles are unevenly dispersed on said first phosphor layer, and the dispersion density of the phosphor particles increases along a radial direction from the center of said phosphor layer, as viewed from top of said phosphor layer.

31. The method according to claim 28, wherein said phosphor particles are unevenly dispersed on said first phosphor layer, and the dispersion density of the phosphor particles decreases along a radial direction from the center of said phosphor layer, as viewed from top of said phosphor layer.

32. The method according to claim 28, wherein said phosphor substance is in the form of particles and the phosphor particles are unevenly dispersed on said first phosphor layer, and the dispersion density of the phosphor particles has an undulating distribution radially spreading out from the center of said phosphor layer, as viewed from top of said phosphor layer.