Method of making optical light engines with elevated LEDs and resulting product
AssigneeLighting Science Group Corporation
InventorsGreg Blonder, Shane Harrah
Life of this patent
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Abstract
An optical light engine is fabricated by providing a thermally conductive base having one or more mounting pedestals for elevating one or more LED die above the base's surface. The LED die are mounted on the pedestals, electrically connected, and a mold having a molding surface for molding a dome centered around the LED die is disposed on the base over the pedestal-mounted LED die. The encapsulating material is then injected through an input port disposed in the base to mold the dome around the LED die. The encapsulant material is cured and the mold is removed. In an advantageous embodiment, the light engine comprises a ceramic-coated metal base made by the low temperature co-fired ceramic-on-metal process (LTCC-M).
Claims44
A method of fabricating an optical light engine comprising the steps of:
- providing a base comprising a pedestal for supporting one or more LED die, an input port, and an output port;
- mounting one or more LED die on the pedestal;
- disposing a mold over one or more of the LED die, wherein the mold is adapted to mold a dome approximately centered about the pedestal;
- injecting a molding material through the input port and removing excess molding material through the output port;
- curing the molding material;
- and
- removing the mold.
An optical light engine comprising:
- a base including an input port and an output port;
- a pedestal adapted to support one or more LED die above a surface of the base;
- one or more LED die mounted on the pedestal;
- and
- a dome disposed over one or more of the LED die, wherein the dome is formed by injecting a molding material into a mold through the input port of the base and excess molding material is removable via the output port of the base.
An optical light engine array comprising:
- a common base including one or more input ports and one or more output ports;
- at least two pedestals, wherein an LED die is mounted on each pedestal such that the LED die is positioned above a surface of the common base;
- and
- a dome disposed over each of the pedestals, wherein each dome is formed by injecting a molding material into a mold through at least one of the input ports of the common base and excess molding material is removable via at least one of the output ports of the common base.
Dependencies are inferred from the claim text.