SURFACE EMITTER WITH LIGHT-EMITTING AREA EQUAL TO THE LED TOP SURFACE AND ITS FABRICATION

摘要

A method includes forming a wavelength converting layer on a first support, placing light-emitting diodes (LEDs), with their top-emitting surfaces facing down, on the wavelength converting layer, curing the wavelength converting layer so the top-emitting surfaces of the LEDs adhere to the wavelength converting layer, singulating the LEDs by cutting the cured wavelength converting layer between the LEDs, wherein after said singulating each LED has a wavelength converter that exactly overlaps or slightly extends beyond a top-emitting surface of the LED, forming a reflective layer over and in-between the LEDs, curing the reflective layer, wherein the cured reflective layer has a hardness and an abrasion rate greater than the cured wavelength converting layer, and removing a top portion of the cured reflective layer to expose the LEDs.