Method and Apparatus for a Flat Top Light Source

A method for making a plurality of light-emitting devices, the method comprising:

• attaching a plurality of light source dies on a substrate;
• aligning a casting member having at least one cavity to the substrate such that the plurality of light source dies are enclosed within the at least one cavity;
• fixing the position of the casting member relative to the substrate using a casting jig;
• premixing an encapsulant in liquid form having a wavelength-converting material;
• dispensing the encapsulant into the at least one cavity;
• allowing the wavelength-converting material to precipitate and form thereon a high density layer, and a low density layer, wherein the high density layer comprises precipitated wavelength-converting material and the low density layer comprises the wavelength-converting material suspending within the encapsulant in particle form;
• curing the encapsulant layer into solid form;
• removing the casting member and the casting jig;
• and
• isolating each individual light-emitting device.

A flash used in mobile devices, comprising:

• a flat substrate, the substrate having top and bottom surfaces;
• a light source die attached on the top surface;
• an encapsulation layer encapsulating the light source die and the top surface, wherein the encapsulation layer further comprises:
• a layer of low density wavelength-converting material, the wavelength-converting material being in particle form suspended within the encapsulation layer;
• and
• a layer of high density precipitated wavelength-converting material substantially planarly parallel to the top surface.