SHALLOW REFLECTOR CUP FOR PHOSPHOR-CONVERTED LED FILLED WITH ENCAPSULANT

An LED die conformally coated with phosphor is mounted at the base of a shallow, square reflector cup. The cup has flat reflective walls that slope upward from its base to its rim at a shallow angle. The reflective walls are in contact with the phosphor. A clear encapsulant completely fills the cup to form a smooth flat top surface. Emissions from the LED die or phosphor at a low angle are totally internally reflected at the flat air-encapsulant interface toward the cup walls. This combined LED/phosphor light is then reflected upward by the walls and out of the package. Since a large percentage of the light emitted by the LED and phosphor is mixed by the TIR and the walls prior to exiting the package, the color and brightness of the reflected light is fairly uniform. The encapsulant is intentionally designed to enhance TIR to help mix the light.