Light emitting diode with thin multilayer phosphor film

Abstract

A multiple layer film and a method of manufacturing the same, the film having a phosphor bearing layer including phosphor and a carrier, and a rigid protective layer. In some embodiments a mixture including phosphor and an uncurable fluid are dispensed onto a surface, and the mixture is at least partially dried. A curable fluid is dispensed onto the at least partially dried mixture, and the curable fluid is cured.

1 . A method of manufacturing a film, comprising:
 dispensing a mixture comprising phosphor and an uncurable fluid onto a surface;   at least partially drying the mixture;   dispensing a curable fluid onto the at least partially dried mixture; and   curing the curable fluid.   
     
     
         2 . The method of  claim 1 , further comprising further drying the mixture after dispensing the curable fluid and prior to the curing of the curable fluid. 
     
     
         3 . The method of  claim 1 , wherein the uncurable fluid comprises an uncurable silicone fluid. 
     
     
         4 . The method of  claim 1 , wherein the curable fluid comprises a curable silicone fluid. 
     
     
         5 . The method of  claim 1 , wherein the curable fluid is transparent. 
     
     
         6 . The method of  claim 1 , wherein the mixture further comprises treated silica. 
     
     
         7 . The method of  claim 1 , further comprising sonicating the mixture prior to the dispensing of the mixture onto the surface. 
     
     
         8 . The method of  claim 1 , further comprising applying at least a partial vacuum to the film during the at least partially drying the mixture. 
     
     
         9 . The method of  claim 1 , wherein the surface comprises an inner surface of a package and a surface of a light emitting diode in the package. 
     
     
         10 . The method of  claim 9 , wherein the surface of the light emitting diode comprises a side wall surface and a top wall surface of the light emitting diode. 
     
     
         11 . (canceled) 
     
     
         12 . An article of manufacture prepared by a process comprising:
 depositing a composition comprising phosphor and an uncurable liquid onto a light emitting device;   at least partially drying the composition;   depositing a curable liquid on the composition; and   curing the curable liquid.   
     
     
         13 . The article of manufacture of  claim 12 , prepared by the process further comprising further drying the composition after dispensing the curable liquid and prior to the curing of the curable liquid. 
     
     
         14 . The article of manufacture of  claim 12 , wherein the uncurable liquid comprises uncurable silicone. 
     
     
         15 . The article of manufacture of  claim 12 , wherein the curable liquid comprises curable silicone. 
     
     
         16 . The article of manufacture of  claim 12 , wherein the curable liquid is transparent. 
     
     
         17 . The article of manufacture of  claim 12 , wherein the composition further comprises treated silica. 
     
     
         18 . The article of manufacture of  claim 12 , prepared by the process further comprising sonicating the composition. 
     
     
         19 . The article of manufacture of  claim 12 , prepared by the process further comprising applying at least a partial vacuum during the at least partially drying the composition. 
     
     
         20 . The article of manufacture of  claim 12 , wherein the light emitting device comprises an inner surface of a package and a surface of a light emitting diode in the package. 
     
     
         21 . The article of manufacture of  claim 12 , wherein the surface of the light emitting device comprises a side wall surface and a top wall surface of the light emitting device. 
     
     
         22 - 34 . (canceled)