Fabrication of LED lamps by controlled deposition of a suspension media

Abstract

A method of manufacturing an LED lamp includes dispersing color correction particles throughout a suspension media to a viscosity of substantially 2000 cP. In the case of correcting blue GaN LEDs to white light, the particles to be blended are phosphorus having a diameter of less than 20 microns. An LED die is mounted onto a stage and a nano-liter pipette is arranged such that an interface separation of approximately 1 millimeter is achieved between the tip of the pipette and the surface of the LED die. Once the relatively viscous suspension media covers the LED die, ultraviolet light is directed towards the suspension media to cure it. Heat is then applied to further cure the suspension media until solid as observed under a microscope.

Dependencies are inferred from the claim text.