100 LPW 800 Lm Warm White LED

Abstract

An illumination grade warm white (WW) LED, having correlated color temperature (CCT) between 2800 K and 3500K and capable of producing 800 lm output at 100 lm/W, has been developed in this program. The high power WW LED is an ideal source for use as replacement for incandescent, and Halogen reflector and general purpose lamps of similar lumen value. Over the two year period, we have made following accomplishments: developed a high power warm white LED product and made over 50% improvements in light output and efficacy. The new high power WW LED product is a die on ceramic surface mountable LED package. It has four 1x1 mm{sup 2} InGaN pump dice flip chip attached to a ceramic submount in 2x2 array, covered by warm white phosphor ceramic platelets called Lumiramica and an overmolded silicone lens encapsulating the LED array. The performance goal was achieved through breakthroughs in following key areas: (1) High efficiency pump LED development through pump LED active region design and epi growth quality improvement (funded by internal programs). (2) Increase in injection efficiency (IE) represented by reduction in forward voltage (V{sub f}) through the improvement of the silver-based p-contact and a reduction in spreading resistance. Themore » injection efficiency was increased from 80% at the start of the program to 96% at the end of the program at 700 mA/mm{sup 2}. (3) Improvement in thermal design as represented by reduction in thermal resistance from junction to case, through improvement of the die to submount connection in the thin film flip chip (TFFC) LED and choosing the submount material of high thermal conductivity. A thermal resistance of 1.72 K/W was demonstrated for the high power LED package. (4) Improvement in extraction efficiency from the LED package through improvement of InGaN die level and package level optical extraction efficiency improvement. (5) Improvement in phosphor system efficiency by improving the lumen equivalent (LE) and phosphor package efficiency (PPE) through improvement in phosphor-package interactions. Another achievement in the development of the phosphor integration technology is the demonstration of tight color control. The high power WW LED product developed has been proven to have good reliability. The manufacturing of the product will be done in Philips Lumileds LUXEON Rebel production line which has produced billions of high power LEDs. The first high power WW LED product will be released to the market in 2011.« less