# US 8,771,577 B2 · Light emitting device with molded wavelength converting layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,771,577 B2 - Document ID: US8771577B2 - Status: Granted - Kind: B2 - Application number: 12/706,149 - Filed: 2010-02-16 - Published: 2011-08-18 - Granted: 2014-07-08 - Earliest claimed: 2010-02-16 - Assignees: Koninklijke Philips N.V.; Philips Lumileds Lighting Company, LLC - Applicants: Grigoriy Basin; Paul S. Martin - Inventors: Grigoriy Basin; Paul S. Martin - Web page: https://patentgrep.com/patent/US8771577B2 ## CPC - H10H 20/8513: {having two or more wavelength conversion materials} - B29C 43/18: incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} - H10H 20/0137: {the light-emitting regions comprising nitride materials} - H10H 20/851: Wavelength conversion means - H10H 20/854: characterised by their material, e.g. epoxy or silicone resins - H10H 20/855: Optical field-shaping means, e.g. lenses - H10H 20/01: Manufacture or treatment - H10W 90/00: Package configurations - H10H: INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - H10W: GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10 ## Abstract A flexible film comprising a wavelength converting material is positioned over a light source. The flexible film is conformed to a predetermined shape. In some embodiments, the light source is a light emitting diode mounted on a support substrate. The diode is aligned with an indentation in a mold such that the flexible film is disposed between the support substrate and the mold. Transparent molding material is disposed between the support substrate and the mold. The support substrate and the mold are pressed together to cause the molding material to fill the indentation. The flexible film conforms to the shape of the light source or the mold. ## Claims ### Claim 1 A method comprising: positioning a flexible film over a light source, the flexible film comprising a transparent material filled with wavelength converting material; and aligning the light source with an indentation in a mold such that the flexible film is disposed between the light source and the mold; disposing transparent molding material between the light source and the mold; and pressing the light source and the mold together to cause the molding material to fill the indentation and to cause the flexible film to conform to a predetermined shape. ### Claim 2 (depends on 1) The method of claim 1 wherein the light source comprises a III-nitride light emitting diode mounted on a support substrate. ### Claim 3 (depends on 2) The method of claim 2 wherein the flexible film is in direct contact with the light emitting diode and conforms to a shape of the light emitting diode. ### Claim 4 (depends on 2) The method of claim 2 wherein the flexible film is in direct contact with the mold and conforms to a shape of the indentation. ### Claim 5 (depends on 2) The method of claim 2 wherein the flexible film comprises a powder phosphor disposed in a silicone film. ### Claim 6 (depends on 5) The method of claim 5 wherein the silicone film is fully cured prior to said positioning. ### Claim 7 (depends on 5) The method of claim 5 wherein the silicone film is partially cured prior to said positioning. ### Claim 8 (depends on 5) The method of claim 5 wherein the flexible film further comprises a non-wavelength converting material, wherein the non-wavelength converting material changes an index of refraction of the flexible film. ### Claim 9 (depends on 2) The method of claim 2 wherein the flexible film is disposed on a support film. ### Claim 10 (depends on 9) The method of claim 9 further comprising removing the support film after pressing the light source and the mold together. ### Claim 11 (depends on 2) The method of claim 2 wherein the indentation is shaped as a lens. ### Claim 12 (depends on 2) The method of claim 2 wherein the flexible film is a first flexible film in direct contact with the light emitting diode, the method further comprising: positioning a second flexible film comprising a wavelength converting material in direct contact with the mold; wherein the transparent molding material is disposed between the first flexible film and the second flexible film. ### Claim 13 (depends on 2) The method of claim 2 wherein pressing the light source and the mold together to cause the molding material to fill the indentation and to cause the flexible film to conform to a predetermined shape comprises creating a reduced pressure environment which draws the molding material into the indentation. ### Claim 14 (depends on 1) The method of claim 1 wherein the flexible film is made by evenly spreading a mixture of phosphor and silicone over a support film then at least partially curing the silicone. ### Claim 15 (depends on 1) The method of claim 1 further comprising heating the mold after pressing the light source and the mold together. ### Claim 16 (depends on 15) The method of claim 15 wherein the mold is heated to a temperature that hardens the molding material. ### Claim 17 (depends on 1) The method of claim 1 wherein: the light source is a first light source; the method further comprises mounting the first light source and a second light source on a support substrate; aligning the light source with an indentation in a mold comprises aligning the mold such that the first light source is aligned with a first indentation and the second light source is aligned with a second indentation; and positioning a flexible film over a light source comprises positioning the flexible film such that wavelength converting material is positioned in a space between the first light source and the second light source. ### Claim 18 (depends on 17) The method of claim 17 wherein after pressing the light source and the mold together, a continuous layer of wavelength converting material is disposed over the first light source, the second light source, and the space between the first light source and the second light source. ### Claim 19 (depends on 1) The method of claim 1 wherein a thickness of wavelength converting material in the flexible film is uniform.