TW200423821A - Illumination system using a plurality of light sources - Google Patents
Illumination system using a plurality of light sources Download PDFInfo
- Publication number
- TW200423821A TW200423821A TW092133837A TW92133837A TW200423821A TW 200423821 A TW200423821 A TW 200423821A TW 092133837 A TW092133837 A TW 092133837A TW 92133837 A TW92133837 A TW 92133837A TW 200423821 A TW200423821 A TW 200423821A
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- Prior art keywords
- array
- optical
- led
- light
- lighting device
- Prior art date
Links
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Classifications
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
- G02B6/0005—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being of the fibre type
- G02B6/0008—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being of the fibre type the light being emitted at the end of the fibre
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
- B60Q1/00—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor
- B60Q1/0011—Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor with light guides for distributing the light between several lighting or signalling devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
- F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
- F21S41/141—Light emitting diodes [LED]
- F21S41/143—Light emitting diodes [LED] the main emission direction of the LED being parallel to the optical axis of the illuminating device
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
- F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
- F21S41/141—Light emitting diodes [LED]
- F21S41/151—Light emitting diodes [LED] arranged in one or more lines
- F21S41/153—Light emitting diodes [LED] arranged in one or more lines arranged in a matrix
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
- F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
- F21S41/141—Light emitting diodes [LED]
- F21S41/155—Surface emitters, e.g. organic light emitting diodes [OLED]
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
- F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
- F21S41/24—Light guides
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
- F21S43/10—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source
- F21S43/13—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source characterised by the type of light source
- F21S43/14—Light emitting diodes [LED]
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
- F21S43/20—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by refractors, transparent cover plates, light guides or filters
- F21S43/235—Light guides
- F21S43/251—Light guides the light guides being used to transmit light from remote light sources
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- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
- G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
- G02B6/0066—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form characterised by the light source being coupled to the light guide
- G02B6/0073—Light emitting diode [LED]
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
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- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/3628—Mechanical coupling means for mounting fibres to supporting carriers
- G02B6/3664—2D cross sectional arrangements of the fibres
- G02B6/3672—2D cross sectional arrangements of the fibres with fibres arranged in a regular matrix array
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
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- G02B6/36—Mechanical coupling means
- G02B6/3628—Mechanical coupling means for mounting fibres to supporting carriers
- G02B6/368—Mechanical coupling means for mounting fibres to supporting carriers with pitch conversion between input and output plane, e.g. for increasing packing density
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- G—PHYSICS
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- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/42—Coupling light guides with opto-electronic elements
- G02B6/4201—Packages, e.g. shape, construction, internal or external details
- G02B6/4249—Packages, e.g. shape, construction, internal or external details comprising arrays of active devices and fibres
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V17/00—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages
- F21V17/10—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening
- F21V17/101—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening permanently, e.g. welding, gluing or riveting
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
- F21W2131/00—Use or application of lighting devices or systems not provided for in codes F21W2102/00-F21W2121/00
- F21W2131/20—Lighting for medical use
- F21W2131/202—Lighting for medical use for dentistry
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
- F21W2131/00—Use or application of lighting devices or systems not provided for in codes F21W2102/00-F21W2121/00
- F21W2131/20—Lighting for medical use
- F21W2131/205—Lighting for medical use for operating theatres
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
- F21Y2115/00—Light-generating elements of semiconductor light sources
- F21Y2115/10—Light-emitting diodes [LED]
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/36—Mechanical coupling means
- G02B6/3628—Mechanical coupling means for mounting fibres to supporting carriers
- G02B6/3664—2D cross sectional arrangements of the fibres
- G02B6/3668—2D cross sectional arrangements of the fibres with conversion in geometry of the cross section
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/42—Coupling light guides with opto-electronic elements
- G02B6/4201—Packages, e.g. shape, construction, internal or external details
- G02B6/4204—Packages, e.g. shape, construction, internal or external details the coupling comprising intermediate optical elements, e.g. lenses, holograms
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/42—Coupling light guides with opto-electronic elements
- G02B6/4201—Packages, e.g. shape, construction, internal or external details
- G02B6/4249—Packages, e.g. shape, construction, internal or external details comprising arrays of active devices and fibres
- G02B6/425—Optical features
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/4805—Shape
- H01L2224/4809—Loop shape
- H01L2224/48091—Arched
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/484—Connecting portions
- H01L2224/4847—Connecting portions the connecting portion on the bonding area of the semiconductor or solid-state body being a wedge bond
- H01L2224/48471—Connecting portions the connecting portion on the bonding area of the semiconductor or solid-state body being a wedge bond the other connecting portion not on the bonding area being a ball bond, i.e. wedge-to-ball, reverse stitch
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/484—Connecting portions
- H01L2224/48475—Connecting portions connected to auxiliary connecting means on the bonding areas, e.g. pre-ball, wedge-on-ball, ball-on-ball
- H01L2224/48476—Connecting portions connected to auxiliary connecting means on the bonding areas, e.g. pre-ball, wedge-on-ball, ball-on-ball between the wire connector and the bonding area
- H01L2224/48477—Connecting portions connected to auxiliary connecting means on the bonding areas, e.g. pre-ball, wedge-on-ball, ball-on-ball between the wire connector and the bonding area being a pre-ball (i.e. a ball formed by capillary bonding)
- H01L2224/48478—Connecting portions connected to auxiliary connecting means on the bonding areas, e.g. pre-ball, wedge-on-ball, ball-on-ball between the wire connector and the bonding area being a pre-ball (i.e. a ball formed by capillary bonding) the connecting portion being a wedge bond, i.e. wedge on pre-ball
- H01L2224/48479—Connecting portions connected to auxiliary connecting means on the bonding areas, e.g. pre-ball, wedge-on-ball, ball-on-ball between the wire connector and the bonding area being a pre-ball (i.e. a ball formed by capillary bonding) the connecting portion being a wedge bond, i.e. wedge on pre-ball on the semiconductor or solid-state body
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- H01L2224/85—Methods for connecting semiconductor or other solid state bodies using means for bonding being attached to, or being formed on, the surface to be connected using a wire connector
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Description
200423821 玖、發明說明: 【發明所屬之技術領域】 本發明係關於發光或照明裝配件及系統。更特定言之 本發明係關於包含複數光源之高耦合效率的照明系統。 【先前技術】 照明系統用於各種應用中。家庭、醫學、牙科及工業靡 用經常需要使用光。同樣,飛機、船舶及汽車應用需要高 強度照明光束。 傳統發光系統採用電力驅動燈絲或弧燈,其有時包括聚 焦透鏡及/或將產生的照明引導至光束内之反射表面。然 而,在特定應用中,例如泳池發光,最後光輸出可能需要 放置於不需要電接觸之環境。其他應用中,例如汽車前燈, 需要將光源從曝露、易遭損壞區移動至更安全位置。此外, 在另一應用中,物理空間限制、可存取性或設計考慮可需 要光源放置於不同於需要最後照明處之位置。 根據一些該等需要,已經發展出採用光學波導將來自夫 源的光料至期望照明點之照明系統。—種目前的方法痛 采用月儿單光源或緊密成群的光源叢集來形成單一照明 源。將此$源所發射之光借助於聚焦光學&置引導至單一 光予波導,例如大核心塑膠光纖,其將光發送至遠離該为 源/該等光源之位置。另—方法中,單—纖維可由單獨光缝 之棒束取代。 本方法效率極低,—些情形中產生的光之損失大約 7〇%。在多重纖維系統中,這些損失可能係由於棒束内
O:\89\89766.DOC 200423821 、之間的黑暗填隙空間及將光引導至纖維棒束内之效率。 早~纖維系統中,具有足夠大直徑以捕獲明亮發光應用所 需之光數量的單一纖維變得太厚,失去以較小半徑發送及 彎曲的靈活性。 —些光產生系統已採用雷射作為光源,利用其同調光輸 出及/或低發散角之優點。然而,雷射光源通常產生單一波 長輸出顏色,而照明系統通常需要更多寬頻白色光源。例 如,美國專利第5,299,222號說明的係採用單一波長高功率 雷射二極體將能量耦合至波長敏感增益媒體中,而非用作 肤明源。指定雷射二極體之使用及其不對稱光束形狀需要 廣泛採用光束成形元件,以便達到對光纖之更有效的耦 °同樣,一些雷射二極體使用費用很高,此係因為由於 ,、乍中產生的熱其品要嚴格的溫度控制(例如,需要採用熱 電冷卻器等等)。此外,封裝式LED之集中陣列可導致熱管 理面積問題。 因此需要可採用光源提供高強度照明的發光系統。 【發明内容】 本發明係關於發光或照明裝配件。更特定言之,本發明 係關於高耦合效率照明系統,其包括遠離照明輸出配置 複數光源。 ' 根據本發明之發光或照明系統本文稱為照明裝置,其包 括複數LED晶粒,對應複數光學波導,各光學波導具有= 一及第二端,每個第一端與對應LED晶粒進行光學互通 以及插入複數LED晶粒與複數光學波導之對應 ^ 碼之間
O:\89\89766.DOC 200423821 的一對應光學元件陣列。 示範性具體實施例中,光源係單獨led晶粒或晶片,或 者雷射二極體。波導可包括光纖,例如聚合物包覆石英纖 維。複數光學波導之第一端接收從光源發射之光。複數光 學波導第二端可捆束或配置成陣列,當照射時形成單一光 照明源。 光學元件可包括被動光學元件,例如輸入光引導或集中 70件陣列,其中每個波導第一端與至少一個光引導/集中元 件進行光學互通,且其中光引導/集中元件陣列插入LEd晶 粒與複數光學波導第一端之間並與其進行光學互通。 示範性具體實施例中,光學元件陣列包含反射器陣列。 這些反射器形狀可設定成保留或保持LED晶粒光源較小實 體’或者實質上將此實體匹配光接收纖維之實體(其與核心 面積及接收角之乘積成比例)。反射器陣列可形成於一基板 上’例如多層光學膜(multilayer optical film ; M〇F)或金屬 化基板或薄板。 照明裝置可進一步包含至少一個輸出光引導元件,例如 準直、集合或引導來自第二端的光以形成單一照明源之光 束成形元件。輸出光引導元件可包含光引導元件陣列,其 中每個第二端與至少一個光引導元件進行光學互通。 或者,複數波導可包含複數光纖且輸出光引導元件包含 複數光纖之每個第二端上的纖維透鏡。同樣,光纖第一端 可進一步包含纖維透鏡。 另-具體實施例中,照明裝置進-步包括第二複數·
O:\89\89766.DOC 200423821 晶粒及第二複數光學波導,各具有第一及第二端,第二複 數光學波導之每個第一端與第二複數led晶粒之一進行光 學互通。一示範性具體實施例中,第二複數光學波導之第 二端可與第一複數光學波導之第二端一起捆束,當照射時 形成單一光照明源。或者,第一複數光學波導之第二端形 成於第一棒束内,第二複數光學波導之第二端形成於第二 棒束内,形成可以相同或不同方向引導的分離照明輸出。 這些第一及第一光源可具有不同發射頻譜。一特定具體 實施例中,第一複數LED晶粒之發射頻譜本質上為白光, 而第二複數LED晶粒包括紅外線光源。另一具體實施例 中,兩個(或更多)複數LED晶粒包括不同顏色,以便提供混 合非白色。第一及第二複數LED晶粒可單獨或共同地照 射,以改變照明源之強度。 此外,該系統可包含至少一個輸出光學元件,其光學耦 合成沿第-路徑引導來自帛光學波導之第二端的輸 出光,以及第二輸出光學元件,其光學搞合成沿第二路徑 引導來自第二複數光學波導之第二端的輸出光。 此類具體實施例可作為用力汽車或其他車幸兩或平臺之前 燈照明系統來應用。-項示範性具體實施例中,前燈光束 之強度可藉由照射光源陣列的特定數量之led晶片來控 制。例如,第一複數LED晶粒可為低光束照射,第一及/ = 第二複數LED晶粒可為高光束照射。 另一示範性具體實施例中’照明系統可進一步包含紅外 線感測器,用於例如碰撞偵測、照明及/或遙測應用。
O:\B9\89766.DOC -9- 200423821 本發明概要並非說明每個解說的具體實施例或本 =母項實辭驟。下㈣圖式及詳細說明㈣例示這 些具體實施例。 【實施方式】 U ^光學纖維發光設計有高㉟合損失的缺點,因 此效率極低。依據本發明之照明“提供實質上較高的光 輕合效率。另彳,本發明之照明系統提供對於人類觀察者 =同起源於單-光點之不同調光輸出。此外,本發明之示 範丨生/、體只加例顯示LED晶粒陣列可用於提供可在一或多 個位置輪出的高密度遠端光源。此外,本發明之示範性具 體實施例提供高密度、遠端光源,其可在一或多個位置單 獨或同時產生一種顏色或多種顏色。此外,光源之顏色或 顏色組合可改變,以便隨著操作過程中使用狀況改變而適 a應用之特疋要求。以下說明其他示範性具體實施例。 圖1說明依據本發明之具體實施例的遠端發光系統1〇〇之 示範性第一具體實施例。亮度LED晶粒1〇4之陣列ι〇2定位 成與光學元件110陣列光學對準,其可包括複數被動光學元 件’例如聚焦透鏡112或光學集中元件,例如反射器120(見 圖2)。光學元件11〇陣列依次光學對準至波導陣列124,其 可包括複數光學波導,例如光學纖維122。波導陣列124可 連接至連接器,其中連接器連結可包括連接器132,用以支 援及/或容納纖維122之光接收端。連接器連結亦可包括連 接器130,用以支援及/或容納纖維122之輸出端。圖8至11 顯示示範性連接器結構,並在以下說明。熟習本說明書所 O:\B9\89766.DOC -10- 200423821 提供之技術的人士應明白,纖維122之輸出端可捆束,形成 點狀光源或成形陣列,例如線性陣列、圓形陣列或其他形 狀陣列。 陣列102由離散LED陣列1〇4製造,例如單一 LED晶粒或晶 片陣列,其單獨安裝並具有用於操作控制(而非全部led藉 由其共同半導體基板彼此連接的LED陣列)之獨立電性連 接^ LED晶粒可產生對稱輻射圖案,使其符合本發明之光 源的需要。LED晶粒能有效地將電能量轉換為光,且與大 多數雷射二極體一樣對溫度不敏感。因此,LED晶粒可採 用與奔多類型雷射二極體相比較少的熱吸收器充分地操 作。一示範性具體實施例中,每個LED晶粒藉由至少大於 LED晶粒寬度之距離與最近鄰近晶粒隔開。 此外,LED晶粒可在從之溫度操作,並且可 具有100,000小時範圍内的操作壽命,相比之下大多數雷射 二極體壽命大約為10,000小時,或鹵素汽車前燈壽命為5〇〇 至1〇〇〇小時。一示範性具體實施例中,LED晶粒可各具有 大約50流明或更多的輸出強度。離散高功率LED晶粒可從 (例如)Cree及〇sram的公司購得。一示範性具體實施例中, LED晶粒陣列(由Cree製造)各具有大約3〇〇 μιηχ3〇〇 的發 射面積,可用於提供集中(小面積、高功率)光源。亦可採用 其他發光表面形狀,例如矩形或其他多角形狀。此外,替 代具體實施例中,採用的LED晶粒之發射層可位於頂部或 底部表面。 替代具體實施例中,LED陣列可用於白色VCSEL陣列取
0:\89\89766,D0C -11- 200423821 代。被動光學元件陣列110可用於將發射自每個VCSEL的光 重新引導至對應纖維122内。 圖1說明的具體實施例之方面為每個光源、對應被動光學 元件(透鏡、聚焦、集中或反射元件)及對應波導之間的一對 一 一致性。當有電源時,每個lED晶粒104作為將光發射至 對應撓性單獨纖維122的單獨光源。本示範性具體實施例包 括大核心(例如400 μχη至1000 μΓη)聚合物包覆石英纖維(例 如以商標TECS在市場上銷售,可從明尼蘇達州聖保羅市3Μ 公司購得)。其他類型的光纖,例如傳統或專用玻璃纖維亦 可依據本發明之具體實施例使用,其取決於例如LED晶粒 光源之輸出波長的此類參數。 此外’熟習本說明書所提供之技術的人士應明白,其他 波導類型,例如平面波導、聚合物波導等等,亦可依據本 教導内容使用。 光學纖維122可進一步包括光學纖維每個輸出端上的纖 維透鏡。同樣,光纖之光接收端各可進一步包含纖維透鏡。 纖維透鏡製造及實施在共同持有、共同待審的美國專利申 請案第10/317J34及10/670,630號中說明,其以提及方式併 入本文中。 以下進一步詳細說明之本發明的一項特定具體實施例 (圖13中說明)係採用撓性TECS纖維將光源及前燈互連的 LED驅動汽車前燈之實施。此具體實施例之一方面係 光以用減少數量之LED光源產生需要照度及光束圖案之方 式有效耦合至TECS纖維。 O:\89\89766.DOC -12- 200423821 如圖2所說明,成形反射器120可新增至每個LED晶粒 104,將來自LED晶粒104之光重新引導至對應纖維122内, 其可具有大約600 μπι至650 μπι的示範性核心直徑。一示範 性具體實施例中,每個反射器之結構向光接收纖維提供非 成像光集合及照明分佈。成形反射器120可由多層光學膜 (MOF)製成,例如可從明尼蘇達州聖保羅市3Μ公司購得的 增強型鏡面反射(Enhanced Specular Reflector ; ESR)膜。 MOF範例通常在美國專利第5,882,774及5,8〇8,794號中詳細 說明,其以提及方式整體併入本文中。 或者,反射器120可在金屬或塑膠基板或薄板内以適當形 狀形成’並使用反射材料塗佈,例如銀、銘或無機薄膜之 反射多層堆疊。例如,可能形成射出模製塑膠膜或薄板。 形成於其中的反射器腔可使用合適的反射材料塗佈。如本 文所述,反射器陣列可定位於LED晶粒下方、周圍或上方。 此外,反射器腔可使用索引匹配材料填充。 再參考圖1,單獨纖維122集合在一起,在距原始光源一 距離處提供遠端發光。一特定具體實施例中,纖維122—起 變為輸出連接器130内的嚴密棒束,其可取代例如聚光燈或 月燈裝配件内的燈泡或燈泡燈絲。基於led之發光裝配件 (其作為燈泡取代物植入)的進一步說明係在標題為「固態發 光裝置」(律師檔案號碼59349US002)的共同待審、共同持 有申請案中說明,其以提及方式併入本文中。 再參考圖2,在一示範性具體實施例中,可使用裸藍或lED 晶粒。一些示範性具體實施例中,LED晶粒較佳的係使用
O:\89\89766.DOC -13- 200423821 磷光體層106(例如YAG:Ce磷光體)塗佈在發光表面上。磷光 體層106可用於將led晶粒之藍輪出轉換至r白色」光。 一替代具體實施例中,紅色、藍色及綠色LED晶粒之集 合可選擇性地置於陣列内。最終發射藉由纖維122陣列集 合,以便自纖維輸出端發射的光混合在一起時作為彩色光 或「白色」光由觀察者看見。 如圖2所示,磷光體層可安裝或形成於LED晶粒發射表面 之上。本發明之一示範性具體實施例中,如圖15所示,磷 光體層506可精確地定義,以便實質上保留或減少led晶粒 表面發射實體的降級。「實質上保留」意味著LED晶粒實體 保持或增加二的因數或更少。 如圖15所示,磷光體層5〇6形成於led晶粒504上,其係 女裝於基板540上之表面。一範例中,LED晶粒5〇4係藍色 或UV表面發射LED。基板540為LED晶粒陰極及陽極存取提 供傳導表面。例如,一或多個電線焊接545可從基板之電接 觸表面541耦合至置於LED晶粒5〇4之頂部表面上的一或多 個焊墊546。或者,電線焊接545可不需要焊接至led晶粒 之頂部表面。 磷光體層506置於LED晶粒之實質上對應其發射表面的 區域之上或附近。應瞭解LED晶粒通常透過一個以上表面 發射輻射。層506可形成為實質上均勻的厚度(例如大約75_ 至大約150 μηι)並(部分或完全)固化。此示範性具體實施例 中’層506接著可藉由刻除、晶粒切割或其他具有最小表面 變形的合適技術轉換至一個或多個形狀,以便匹配LED晶
O:\89\89766.DOC -14- 200423821 粒發射表面之形狀。或者,可使用尺寸過小或尺寸過大層 =6,或形成不同於LED晶粒發射表面之形狀。當使用^^= 晶粒陣列時,磷光體層可直接形成於每個晶粒表面 上,或者磷光體層可為施加於LED晶粒陣列表面或附近之 選擇性圖案化磷光體層之分離、塗佈膜的部分。以下進一 步說明的額外磷光體方位係在標題為「多LED光源及用於 組合其之方法」(律師檔案號碼59376us〇〇2)的共同待審、 共同持有申請案中說明,其以提及方式併入本文中。 示範性具體實施例中,磷光體層5〇6作為填光體負载密 封形成。例如,可使用YAG:Ce磷光體&uv固化環氧樹脂(例 如Norland N0A81UV固化環氧樹脂)。磷光體負載密封可部 分或完全固化。在部分固化狀態中,磷光體密封將流向電 線焊接周圍,將電線焊接封裝並將磷光體及電線焊接黏接 至晶粒表面。若採用疏水密封材料,可改進電互連之可靠 性。磷光體密封可為低模數材料,以便將由於LED晶粒溫 度升/降而引起的不利影響減至最小。此處,LED晶粒材料 與磷光體材料間的熱膨服係數(c〇e^Yicient 〇f thermal expansion ; CTE)失配可藉由此一可變形密封補償。 若磷光體密封完全固化,額外黏性層(具有大約與電線焊 接相同之厚度)可置於LED晶粒表面。例如,額外黏性層可 藉由沈積或浸塗技術形成於LED晶粒表面。因此,可使用 額外黏性層來封裝電線焊接且鱗光體密封可放置成與led 晶粒表面無空隙地接觸(經由黏合劑)。 上述定義明確之磷光體層構造可用於實質上保留led晶 O:\89\89766.DOC -15- 200423821 粒之發光表面的實體。此範例中,磷光體層之面積形成為 與發光表面之面積大約相同。此外,磷光體層之厚度可控 制為合適數量,因為隨著磷光體層厚度增加,發射自磷光 體層側面之光的數量亦增加。此外,色溫及色均勻度參數 可用於決定用於特定應用的正確磷光體層厚度。 一替代具體實施例中,如圖16所示,磷光體層之形狀可 進一步定義為實質上保留LED晶粒光源之實體。此處,lED 晶粒504經由電線焊接545耦合至基板54〇,其包括接觸表面 541如上所述,填光體層506形成於LED晶粒504的發光表 面之上。此外,進一步刻除或分割技術可用於在磷光體層 506上形成有角度表面5〇7。 再參考圖2,反射器120可用於將發射自LED晶粒1〇4的光 耦合至纖維122。同樣,如圖2所示,反射器可形成為可在 led晶粒上滑動,以便其較低開口 123緊密配合LED晶粒1〇4 周邊周圍。替代反射器設計包括支援LED晶粒之基板的反 射塗層之額外使用。其他反射器設計在標題為「反射光耦 合器」(律師檔案號碼59121US002)的同時歸檔、共同持有、 共同待審專利申請案中詳細說明,其以提及方式併入本文 中。 此光學系統之一重要方面為反射器120之反射表面121的 形狀。反射器120可藉由射出成型、轉移成型、微複製、衝 壓、沖斷或熱壓成型形成。反射器12〇可形成於其中(單個 或作為反射器陣列之部分)的基板可包括各種材料,例如金 屬、熱塑性材料或MOF。用於形成反射器120之基板材料可
O:\89\89766.DOC -16- 200423821 用反射塗層塗佈或簡單地研磨,讀增加其反射率。 反射器表面121之形狀設計成將來自LED晶粒(包括磷光 體塗佈LED晶粒)的同向性發射轉換至滿足光接收纖維(例 如TECS纖維)之接收角標準的光束,從而保留發射自l叩晶 粒的光之功率检度。—旦藉由LED晶粒發射的光集合並藉 由反射抑重新引導至光接收纖維,纖維可用於以較低光學 損失藉由總内部反射將光傳輸至較遠位置。然而,光接收 纖維不僅用作傳輸光。此外,依據本發明之具體實施例, 藉由將來自較寬led晶粒陣列間隔的纖維轉化為嚴密的一 個或多個間隔,例如嚴密封包式纖維棒束,來自廣泛分散 LED陣列的光可有效地集中到極小區域。同樣,由於纖維 輸入知以及輸出端之數值孔徑(Numerical Aperture ; NA), 不範性TECS纖維核心及包覆之光學設計用於使自捆束端 發出的光束成形。如本文所述,光接收纖維執行光集中及 光束成形,以及光運輸。 實體ε可使用下列公式計算: ε = Α*Ω 三 π*Α* sin20 = π * A * ΝΑ2 其中: Ω為發射或接收之立體角(球面度中); A為接收器或發射器之面積, Θ為發射或接收角,以及 NA為數值孔徑。 例如,假定ΝΑ為0.48且直徑纖維核心為600微米(μηι),可 由纖維接收及發送的實體大約為0.2 mm2球面度(sr)。亦假 O:\89\89766.DOC -17- 200423821 定不範性LED晶粒之最大發射表面大約為3〇〇 μιηχ3〇〇 (或90000 μηι2),並在在磷光體之示範性實施例中,led晶 粒具有幾乎同向性或漫射之強度分佈。假定半角為8〇度, LED晶粒實體大約為〇·28 mm2 sr。因此,雖然並非全部來自 LED晶粒的光可藉由纖維集合,很大百分比的光(5〇 %或更多) 可藉由使用上述反射器表面設計及方位的光接收纖維集合 及發送。 如上所述,在磷光體層用於將光輸出轉換至「白色」光 的一示範性具體實施例中,碟光體層大小及/厚度可限制以 便保留LED晶粒發射表面之實體。 改進或最佳化反射器形狀可增加甚或最大化進入纖維的 光傳送。圖3顯示最佳化用於分散式光源(使用幾乎漫射之 發射)的反射器形狀之通常幾何形狀,其係圖2之反射器表 面121新增角度及座標軸術語後的詳細說明。 圖3之通常幾何形狀顯示對於鏡面上一給定點,來自led 晶粒之光以到達角私打擊鏡面。另外,鏡上此點位於(x,y), 且在此點鏡與垂直方向成角度φ』。鏡面反射光束角度接著可 顯不為· et _ 2 *么=入角 其係相對於垂直方向的進入纖維之入角。 此範例中由纖維及LED施加的發光約束為: 1 .LED/磷光體光源大小:300微米直徑 2· LED/磷光體發射角·· +/·80。 3. TECS纖維大小: 600微米核心直徑 O:\89\89766.DOC -18- 200423821 4.TECS纖维接收角:ΝΛ 0.43^,+A28 7〇 -些假設可在某程度上降低一般性而簡化分析。 以下分析之限制為: •未考慮完全光源大小,因為其係矩形,不同於此模 弋尹的圓形實際光源大小為300微米與3〇〇微米之 平方。 取接近反射器之LED晶粒的部分所發射之高角度光 忽略。 分析假設係: •光以小於±28.7。接收角之角度反射至(或直接進入) 纖維。因此反射光束約束為丨φί ·2φ』丨1 28 7〇。 • LED/磷光體之光發射角幾乎為同向性,因此與垂直 方向之半角可從〇。改變至8〇。。8〇。最大角用於建立 第一分析點之(X,y)座標。 •小於28.7。的發射角可視為直接進入纖維。 •組態為旋轉地對稱(見上述限制)。 對於該分析,反射器曲線最低點假定為由最大發射角控 制的入射角,φ1==90-80=10。。此假設接著為χ值定義y或方位 為Φ」’之反射器的位置。例如,若反射器假定始於圖2之lEd 104以右30微米處,反射器上第一點之(χ,y)位置計算出 330*tan (90-80)或 58 微米。 一旦已知反射器點之y位置,LED/磷光體上最接近點之最 小角可計算為tair、;:;),假定X座標系統始於距LED 300 微米的最遠邊緣(此範例中假定為圓形)。對於y=5 8微米的 O:\89\89766.DOC -19- 200423821 反射點,最小發射角為27.3。。 計算最小及最大發射角,最小及最大反射器角牝可計 算’使得反射射線採用等式丨及上述第一約束進入纖維。繼 續该範例’反射器角可在大約〇·7。與大約25·7。之間。 反射器形狀接著可藉由為小於8〇度最大值的各種角度重 複此計算而在數值上估計。表丨中,角度以一度增量遞減至 大約為29。的纖維接收角。 對於反射器之(X,y)值陣列,藉由此方法產生的遞增反射 器角接著可從最接近選擇(X,y)點的兩個(χ,y)對之局部導 數(差異)估汁。在表大值8〇。角之範例中,初始反射器角為 17.5。。 從圖中可見,藉由此方法產生之曲線的多項式迴歸線係 y=5E-06x4-0.0068x3+3.6183x2-859.5x+76443(R2=1.0),其中 如圖3所示,座標系統原點為(假定為圓形)LEd左邊緣。 下表1顯示用於80度最大發射角之示範性計算及從led 邊緣至反射器邊緣的30微米之間隔距離。從表1中可見,用 於實際曲線之汁算φ」·值在下表的最後行中計算。若實際反射 器將LED光反射至纖維内,這些值以黑體字編碼,若一些 LED光反射至纖維接收角之外部則用斜體字。計算顯示除 鏡面頂部之外,發射光可反射至纖維内。圖4係假定最大發 射角為80度且LED與反射器之間的間隔距離為3〇微米之反 射器點(如本文所概述)的曲線形狀圖。此圖式顯示基於三種 表示法之圓形晶粒模型。中心Y曲線代表從LED晶粒中心至 最近邊緣的最小内切圓,斜線Y代表從晶粒中心至一角的最 O:\89\89766.DOC -20- 200423821 大外接圓,多項式(中心γ)係中心Y資料之多項式符合度。 應注意第4順序多項式係完全符合,第2順序多項式具有尺: 鏡 ^.»f02468024680246802468024680246802 項 θ Χ33333444445555566666777778888899 J f 33333333333333333333333333333333、-地^段 角 至分^09876543210987654321098765432109 岁 87777777777666666666655555555554 4最 亦 部上 面 上使如例 y 8417418 )29 7 5319 7 6544333456 7 914 7 0 56778990112345567890123456780124 1111111111112222222223333 2 5 0 6 3 ····· 12484101496560657201546228 ο· 5297531976544333456791470 曲 。 使0)可一 法(Φ 方直 的垂 内地 維單 纖簡 至分 射部 反米 光 微 1M.3.4.6.9.3.7.2.738407307307419630752964 /f30表 4-765443322111000999888 7 7776665555 方 4+ 田取 222222222222222'—11111,—:—'111-—ill—:—fill 角 η •1 m
.2.5.9.2.5.8.02468023578013467801245 7 8 1112223333344444455555556666666 ***_******** I f f I I * I I I I f I I f * I ~ I I
O:\89\89766.DOC -21 一 a.7.2.7.2.72.7.2727272727272727272727272 ^5544332211009988776655443322 1100 22222222222211111111111111111111
X φ 7· 7· 6·6·6·6· 5· 5· S· 4· 4· 4· 3 3 3 3 2· 2· 2 1·1.1.ο· 11111111111111111111111 ο ο 11 9 6 3 0 7 4 1 9· 9· 9· 9· 8 8 8 5296307418529630730741852 200423821 最大角 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 x 394 396 398 400 402 404 406 408 410 412 414 416 418 420 422 424 426 428 430 432 434 y 354.8 369.3 384.3 400.0 416.3 433.2 450.9 469.4 488.6 508.8 529.9 552.1 575.3 599.8 625.6 652.9 681.7 712.3 744.8 779.3 816.2 最小角 14.8 14.6 14.3 14.0 13.8 13.5 13.2 13.0 12.7 12.4 12.1 11.9 11.6 11.3 11.0 10.8 10.5 10.2 9.9 9.6 9.3 Φ min 6.9 7. 2 3 5 6 7 9 0 丨max 9.7 9.2 7 2 -8 -8 -8 -8 -9 -9 -9 -9 _9 _9 4 7 6 6 5 5 4 4 2 7 2 7.8 7.6 7.3 7.0 6.7 6.5 6.25.9 5.7 2 4 5 7 2 7 2 7 2 7 2 7 2 7 2 0.3 5 5 4 4 4 4 4 3 3 3 3 4 2 9 7 4 2 0 7 5 3 上述反射器設計可在許多不同實施例中實施成陣列圖 案。例如,圖7顯示LED晶粒光源104之示範性陣列,其^ 合至電互連構件142,電互連構件142可置於電路層“I上 (例如撓性電路或半附加撓性電路,包括可從3 m公司購得的 3MTM撓性(或Flex)電路),電路層141可置於基板上。l肋晶 粒104可表面安裝至層141,或在—項替代具體實施例中凹 陷於形成於撓性電路層中的接收孔徑卜作為上述電線焊 接連接的替代’當使用撓性電路時可用LEd陣列替代電互 連。例如,可藉由介電質(聚醯亞胺)之化學移除形成懸臂引 線。此方法可使一個(或兩個)引線成為懸臂,以便用於超音 波或電線焊接至led晶粒上的電接觸。此類懸臂互連引線 可小於電線焊接電線且實質上平坦。
O:\89\89766.DOC -22- 200423821 如上所述’填光體元件106可用於將來自咖晶粒發射頻 譜之光的輸出波導轉換至需要的照明頻譜。同樣,可使用、 對應反射斋120陣列形成被動光學元件陣列11 〇,其可來成 於微複製反射器薄板111内,以便將來自LED晶粒的光有效 耦合至光學纖維122之匹配陣列,例如圖i所示之陣列。反 射器薄板可包括MOF(例如可從3M公司購得的),其中形成 開放反射器腔。或者,薄片111可包括由射出模製材料製成 之反射器120,其中反射塗層(例如銀、鋁、金、無機介電 質堆疊等等)置於或塗佈於内壁上(例如圖2之表面121)。或 者,反射器120可採用反射器形狀之輥壓或沖斷金屬薄片而 形成。 此外’磷光體層106,例如先前所說明的那些,可藉由將 磷光體材料圖案合併至陣列層110之頂部或底部來選擇性 圖案化。雖然圖7顯示正方形LED晶粒陣列,可根據應用要 求採用具有相關聯光學元件、電互連、磷光體元件及反射 形狀的LED光源之規則或不規則陣列。此外,對於此示範 性設計,準標149可用於對準各陣列層。以下參考圖14說明 用於多LED晶粒光源之示範性多層構造。 圖5顯示用於LED晶粒104之示範性安裝結構或基板 140。基板140可提供將熱從LED晶粒104傳導出去的低電阻 熱路徑。此示範性具體實施例中,LED晶粒104置於井151 内,其中裸LED晶粒104可藉由傳統黏著黏接至基板14〇, 例如藉由採用焊接或金屬(例如Au-Sn)迴銲晶粒黏著。基板 140亦可支援一電路層。此示範性具體實施例中,基板14〇 O:\89\89766.DOC -23- 200423821 可使用反射塗層143塗佈。此外,如圖5所示,懸臂引線148 從互連電路層焊接至LED晶粒。 圖5中,磷光體材料106可位於反射器底部,塗佈於層壓 於反射器底部之薄片上,在層壓於反射器底部之薄片上選 擇性圖案化或用較佳方法沈積於LED晶粒頂部。 一示範性具體實施例中,剛性或撓性互連電路層可用於 提供互連。如本文所述,撓性電路材料可從3M公司購得。· 在圖5所示範例中,撓性電路層之介電質(例如聚醯亞胺)部— 刀145可置於反射塗層丨43上。此外,撓性電路層之導電部鲁 刀,例如銅導體及/或其他金屬電鍍層(例如Ni/Au)可置 於用於互連之聚醯亞胺部分1C上。 或者,撓性電路層可反向,裸LED晶粒可位於聚醯亞胺 表面之凹邛分内,直接位於金屬/電路層Μ?上。此替代 具體實施例中,井不必形成於基板材料140内。具有良好熱 傳導性之電性絕緣材料可置於撓性電路的導電部分與基板 j取决於曰曰粒電黏著要求。互連電路之示範性實施{列 才丁題為J明裝配件」(律師檔案號碼59333US002)的同 夺待審〃同持有申請案中說明,其以提及方式併入本文 中。 , 的車又低丨生此,亦可能係較低成本之替代具體實施例 可包㈣㈣統F㈣氧樹脂之電互連印刷線路板結構。另 八體實把例中,低成本電路可藉由在連接LED晶粒陣列 所需要的合適基板上圖案化導電環氧樹脂或導電油墨而製
O:\89\89766.DOC -24- 200423821 如 粒的一對—致性可提供較佳 上所述,纖維對led晶 照明效率。作為此原理之照明,圖6a顯示具有核心125a及 包覆125b的單—纖維125。圖_示十九纖維⑵之棒束 m。例如,對於外#皆為0.028英$,核心直徑大約為㈣ 微米的纖維125,照射棒束127需要的光束之有效面積為大 約0.00Π平方英忖(咖平方公分)。十九個光發送纖維核 心127之面積為大約〇.嶋平方英对(〇 _平方公分)。使 用假定均句分散式錢,麵合至波導的絲量與波導輸入 面積成比例;因此此圖式中光搞合效率比率為細/〇〇17, 或大約60%。 本發明之優點係、&可有效發射至纖維棒束之單獨纖維。 例如,若採用單-錢,由於未受控制光發㈣及進入 纖維包覆之光耦合以及棒束内纖維間之填隙空間,效率可 顯著下降。nut,由於棒束内纖維間的黑暗空間,不會配 合單獨LED與對應纖維之傳統系統可損失發射光之^至 40%。此類系統則需要更多纖維之嚴密捆束卻仍然產生不 集中的光。 相比之下,本發明中,光接收纖維接著可根據纖維直徑 進入很嚴密輸出陣列内,從而產生很緊密、集中的光發射。 由於本發明之單獨光接收纖維直徑相對較小,其可作為 棒束發送並彎曲,棒束可具有各種幾何形狀之斷面,例如 圓形、螺旋形、矩形或其他多角形狀。本發明之示範性具 體實把例使返端驅動來源可集中並重新引導至無法以有效 方式正常獲得發光電源的位置。 O:\89\89766.DOC -25· 200423821 例如,在車輛前燈之應用中,例如圖13所說明,本發明 提t、大小及形狀與燈絲相同的高度集中光源,以便發射的 光可由反射表面或折射元件成形及投射。圖13顯示用於機 動車輛的遠端發光系統300之具體實施例,其包括耦合器 3〇ι,用於將車輛電源(未顯示)耦合至lED晶粒3〇4陣列。 led晶粒304可表面附於互連電路層341,其可置於例如由 上述熱傳導材料製成之基板340上。此具體實施例中,反射 杰形狀320之陣列(例如藉由焊接)可置於互連電路層上,以 母個裸sa粒周邊由反射表面環繞。從晶粒發射並由 反射器陣列集合/集中的光可選擇性地引導朝向透鏡312陣 列,其可將發射的光聚焦至對應纖維322之輸入端。 如圖13所不,輸入連接器332可用於固持纖維322之輸入 端。此示範性具體實施例中,單獨纖維可捆束,形成兩組 纖維351及352,以便光可在不同位置輸出(例如,左右車輛 前燈374及375)。輸出連接器331AA331B可用於固持各前燈 内的捆束纖維組。依此方式,可利用「冷卻」前燈,熱源(即 光產生光源-LED晶粒陣列)遠離最、終照明輸出區域。此配置 可減少對位於前燈内之光學元件的熱損壞,例如反射器、 塗層、透鏡及其他相關光學裝置。 另一示範性具體實施例中,你u圖】以 / 只例如圖13所不之系統3〇〇的照 明系統可進-步包括紅外線感测器。此替代具體實施例 中’-或多個L E D晶粒陣列的可包含紅外線發射l e d晶粒。
此類紅外線LED晶粒可為傳統iR 凡IK LED日日粒,例如可從
Honeywell購得的那此IR LED曰私么认^ 一1^日日粒。糸統可進一步包括傳統
O:\89\89766.DOC -26 - 200423821 IR偵測器,用以接收ir信號。此替代具體實施例可用於碰 撞谓測應用。此外,其他類型的感測器,例如環境光感測 器,可用於自動變暗應用及/或用於在薄暮時自動開燈。因 此,在此替代具體實施例中,本發明之照明系統可提供照 明及遙測。或者,彳包括紅外線收發器,作為照明系統之 整體部分或與之分離地構成。 圖8至11說明各種示範性連接器具體實施例,其可提供低 成本構造並且可用於本文所述之照明系統及裝配件内。 圖8說明用於輸入連接器132a之設計,其有助於纖維122 之頂部及底部負載並以已決定的間距提供η χ n纖維陣列, 其對應於纖維電纜裝配件輸入端之光源陣列。此示範性具 體實施例中,連接器132a由兩片構造形成,頂部部分133具 有齒135 ’其設計成接合底部片134之纖維122。底部連接器 部分134可包括溝槽136,其接收纖維122及齒135,提供安 全配合。此結構不僅提供低成本裝配件,亦使一人可在一 個步驟中組合二維陣列。其他二維連接器設計可要求V型溝 槽連接器之層「堆疊」。 圖9說明η χ η陣列輪入連接器132b,其中纖維122可從頂 部及底部安裝。此示範性具體實施例之連接器13沘由三片 構造形成,其中連接器包括中心部分131,其具有由頂部部 分133’及底部部分134,圍繞之纖維接收溝槽138。或者,連 接裔132b可由單一整合構造形成。此設計亦可在一個步驟 中製造二維連接器。為達到此目的,例如圖12中之裝配件 機可具有兩個纖維陣列,而非一個寬線性纖維陣列。
O:\89\89766.DOC -27- 200423821 二:〇=於具有頂部或底部負載的輪入連接一 /、广物139用於設定纖維間的行間距。此設計亦 =?間隔物」來建立二維陣列而消除堆叠V型溝槽層 圖11說明用於纖維電纔裝配件的輸出連接器130之設 計。此設計可用於頂部負載且可容納纖維122之密集封包, 以便提供集中的照明源。熟f本說明書所提供之技術的人 士應明白,其他連接器設計亦可使用。 圖12說明可用於建構這些裝置的自動化裝配件程序。此 圖示描述線内電繞裝配件⑽ine Cable Assembly; IN㈤ 之方法,其提供同時製造及終止電鏡裝配件之能力。INCA 方法例如在共㈣有美國專利第5,574,817及5,611,⑽號中 說明,其揭示内容以提及方式併入本文中。INCA系統· 由N纖維線軸202組成,纖維饋送給INCA裝配件機21〇。纖 維222使用精確間隔引導梳212以特定、符合需要之間距進 入陣列。通常此間縣終止特定連接器設計所要求之間 距。-旦間距較,纖維發送至連接器裝配件台23〇,其中 由至少一個連接器底部231及一個連接器蓋板232組成之連 接器組件移動至纖維陣列上方及下方之位置。連接器底部 231及蓋板232以纖維陣列長度上的預定間隔一起進一步對 準,然後捕獲陣列之纖、維。連接器裝配件可機械性或黏性 知接至纖維建立終止電緵裝配件,例如透過使用層壓滚 筒240及膠帶242。若組合單—連接器,機器輸出可為連接 至連接器的編線(一端具有連接器之電纜)。藉由在相反位置
O:\89\89766.DOC -28 - 200423821 安裝兩個連接器,稍微隔開、連接至連接器的跨接線電纜 250(兩端皆具有連接器之電纜)從機器輸出。組合連接器及 纖維從連接器連結點繼續穿過機器,保護電鐵護套安裝於 纖維陣列及連接器上。 圖14顯示多層、高密度固態光源4〇〇之分解圖,其可耦合 至光纖,提供與上述具體實施例一致的遠端光源。選擇第 一層或基板440以提供支援LED晶粒404陣列之基極。如上 所述,基板440可包含具有高熱傳導性之材料,例如銅等 等。此外,基板440可導電,並可提供用於LED晶粒4〇4陣 列之電源或接地匯流排。LED晶粒404可使用傳統技術(包括 知接、黏著劑等等)焊接至基板440。黏性層405接著可放置 於LED晶粒上。黏性層405可包括對應LED晶粒位置及間距 的切口圖案。 為提供電性連接,圖案化撓性電路層441接著可置於圖案 化黏性層405上。圖案化撓性電路層441包括電導體圖案 442,提供對LED晶粒404之接觸。通常,LED晶粒需要兩個 電性連接-在一些設計中,一個連接位於Led晶粒頂部,另 一個位於LED晶粒底部,而在其他設計中,兩個連接皆位 於頂部。一些示範性具體實施例中,撓性電路層441包括對 應LED晶粒陣列之切口。連接至LED晶粒之頂部連接經由撓 性電路層441上的電路圖案442製成,底部連接可透過基板 製成。準標449可用於確保基板與撓性電路層441間的正 確對準。 被動光學元件410陣列,例如形成於微複製反射器薄片
O:\89\89766.DOC -29- 200423821 411内之反射器420可用於將發射自LED晶粒之光耦合至對 應光學波導陣列。此示範性具體實施例中,薄片41丨包括反 射器420陣列。反射器420與上述具體實施例一致,可形成 於多層光學膜内或其可包含從反射(例如塑膠、金屬)薄片形 成的模製、機械加工或壓紋形狀,其以與LED晶粒相同的 間距圖案化。此外,反射器亦可包括反射器腔内的透鏡形 狀。另外,圖案化磷光體可包括於反射器腔内,或焊接至 薄片411之頂部或底部。 額外圖案化黏性層445可用於將陣列41〇黏接至撓性電路 層441。此外,準標449可用於對準。黏性材料可選擇成提 供基板及反射器陣列間的高焊接強度及/或絕緣。另外,黏 性材料可減輕由於基板及反射器薄板之熱膨脹係數 (coefficient of thermal expansion ; CTE)間的任何失配而引 起的應力。 一替代具體實施例中,撓性電路層位置及反射器陣列可 互相交換。例如,撓性電路層引線可透過反射器腔發送, 以便黏接至LED晶粒焊塾。 上述照明裝配件及系統具有幾項優於先前系統之優點。 首先,例如上述那些具有較低熱輸出的較小LED晶粒可不 用遭受照明強度之損失。上述範例中,陣列内LED晶粒物 理性分離,以避免安裝結構内的熱性熱點。此結構使 晶粒可更有效地電力驅動,具有更多輸出照明(從而纖維輸 出端可發射更明党之輸出光束)。嚴密封包大量LED晶粒係 涉及長期可靠性問題,因為局部加熱即使具有整體有效熱 O:\89\89766.DOC -30- 200423821 傳導機制,亦可導致減少的LED壽命,極端的情形下可導 致災難性故障。LED晶粒間隔距離較LED晶粒寬度更大使得 熱傳導基板合理地將熱從無局部熱點之LED陣列擷取出 來。若提供足夠熱萃取,LED晶粒亦可在比正常作業說明 曰所述更鬲的電流及光輸出下安全地操作。此外,與燈絲 光源相比,本發明之LED晶粒陣列不會在前導光束内產生 可由燈絲加熱引起的劇烈加熱。此劇烈加熱可導致有時用 於發光元件(例如汽車前燈)的聚合物透鏡及反射器裝配件 之損壞。 第二項優點係每個LED耦合具有一個纖維。先前系統將 led密集陣列耦合至大直徑纖維或纖維棒束。密集陣列 具有上述可靠性問題,但是其實施已證明可提供將光耦合 至纖維的最佳效率(降低可靠性)。每個LED光源提供一個纖 維使LED晶粒可物理性分離,將上述LED密集集中產生之局 部熱效應減至最小。 另一優點係電互連線路。撓性電路(例如上述撓性電路) 所例示之薄電線路(例如25至50微米)層提供電互連、一些來 自晶粒之熱的熱傳導及可層壓之平坦電互連結構。最終構 造總體上係極薄層,以便使此層之光學性能不重要。薄、 平坦層使整體陣列可層壓成高度可靠之固體或幾乎固體的 材料方塊,LED陣列(位於基板上)焊接至電互連層,其可依 -人焊接至反射器薄板。互連電路之特定實施例的優點在標 題為「照明裝配件」(律師檔案號碼593331js〇〇2)的待審、 共同持有申請案中說明,其以提及方式併入本文中。
O:\89\89766.DOC -31 - 200423821 本文說明之照明裝置的額外優點係整體裝配件之疊層或 封裝。由於LED陣列及反射器腔可填充固體材料,例如環 氧樹腊或模製聚碳酸酯,整體裝配件可層壓至無空隙方塊 内 些應用中’電設備中的空隙可產生可靠性問題,因 為水往往在聚合物空隙中集合,導致長期可靠性問題。 同樣’光束形成反射器可置於LED晶粒前方。另外,反 射器結構可由M0F製成,其可繪製成反射器形狀,同時在 可見光波長及廣泛範圍之入射角度上保持反射率。 另一優點係說明的磷光體放置,其提供選擇的輸出顏 色。先前嘗試利用腔内磷光體固持LED。此整體磷光體沈 積需要大置較昂貴之磷光體,由於磷光體同向性地發射 光,此實質上藉由使led看上去大於其實際大小而降級led 光源實體。此依此可顯著減少將光耦合至纖維或其他波導 之效率’如以上具體實施例所說明。 磷光體106,例如圖5所示,可在薄片上塗佈並層壓至反 射器底部(或頂部)之結構内,或者直接置於LED表面。使用 磷光體「塗佈」層在有效地將LED能量轉換為「白色」光 之黏結劑内產生極均勻磷光體薄層。磷光體層可精確定義 成略微增加LED光源之表觀大小,從而保留led實體並改進 系統之耦合效率。當將磷光體負載環氧樹脂直接或間接沈 積於LED的發射表面時,麟光體數量可減少,㈣發射面積 大小可透過極小量磷光體之精確量沈積而精確地保持。 本發明之另一優點係修正從LED晶粒陣列發射之顏色光 譜的能力。雖然「白色」光可由LED晶粒顏色之組合製成,
O:\89\89766.DOC -32- 200423821 數個示範性具體實施例利用磷光體層將藍色或uv輻射轉 換為寬頻譜,即「白色」光。在led晶粒陣列使用不同磷 光體可產生具有需要色溫之「白色」光。同樣,各種顏色 可藉由修正用於led晶粒之磷光體而產生。 雖然磷光體塗佈薄片置於反射器陣列頂部不會產生光能 量至纖維陣列的最有效耦合(由於光纖之有限接收角),此構 造可有利於大表面、高分散陣列,此外沒有來自led密集 集中之局部熱點。 雖然本發明已經參考示範性較佳具體實施例說明,本發 明具體實施成其他特定形式,而不會背離本發明之範圍。 例如’雖然本示範性具體實施例已經在汽車前燈區域内顯 示,本照明系統可用於飛機、輪船、醫學、工業、家庭甚 至其他汽車應用。因此,應明白本文說明並描述之具體實 施例僅為示範性,不應視為限制本發明之範圍。可依據本 發明之範圍作出其他變化及修改。 【圖式簡單說明】 圖1係依據本發明之具體實施例的照明系統之透視圖; 圖2係用於依據本發明具體實施例之照明系統内的光源 之簡化斷面側視圖; 圖3係依據本發明具體實施例之光源及反射器表面的一 部分之詳細圖; 圖4係代表假定最大發射角為80度且Led晶粒與反射器 之間的間隔距離為3 0微米之反射器點的曲線形狀圖之圖 式; O:\89\89766.DOC -33- 200423821 圖5係依據本發明具體實施例《光集中元件的具體實施 例之斷面側視圖; 圖_貝示示範性單一光接收纖維,圖6b顯示示範性光接 收纖維棒束; 圖7係用於依據本發明具體實施例之照明系統内的互連 LED晶粒陣列及光學集中元件陣列之部分分解圖·, 圖8至11係用於依據本發明之照明系統内的光學連接器 之替代具體實施例的斷面端視圖; 圖12係用於同時製造及電纜裝配件終止端之組合設置的 簡化圖; 圖13係依據本發明之具體實施例的車輛照明系統之分解 透視圖; 圖14係多層、高密度固態光源之示範性構造; 圖15及16係磷光體封裝LED晶粒之示範性構造。 雖然對本發明可以有各種修改和替代形式,圖式中係藉 由範例顯示其細節,並且將詳細說明。然而,應當明白, 本發明並不限於所說明的特定具體實施例。相反,本發明 涵蓋了隨附的申請專利範圍中所定義之本發明的精神及範 圍内的所有修改、同等及替代形式。 【圖式代表符號說明】 100 照明系統 102 陣列 104 LED晶粒 106 磷光體層
O:\89\89766.DOC -34- 200423821 110 光學元件 111 薄片 112 聚焦透鏡 120 被動光學元件 121 反射表面 122 光學波導 123 較低開口 124 波導陣列 125a 核心 125b 包覆 125 纖維 127 棒束 130 連接器 131 中心部分 132 連接器 132a 輸入連接器 132b 輸入連接器 132c 輸入連接器 133 頂部部分 133! 頂部部分 134 底部片 1341 底部部分 135 齒 138 纖維接收溝槽 O:\89\89766.DOC -35- 200423821 139 間隔物 140 基板材料 141 電路層 142 電互連構件 143 反射塗層 145 介電質部分 147 導電部分 148 懸臂引線 149 準標 151 井 200 INCA系統 202 纖維線軸 210 INCA裝配件機 212 精確間隔引導梳 222 纖維 230 連接器裝配件台 231 連接器底部 232 連接器蓋板 240 層壓滾筒 242 膠帶 250 連接至連接器的跨接線電纜 300 遠端發光系統 301 柄合器 304 LED晶粒 O:\89\89766.DOC -36- 200423821 312 320 322 331A 331B 332 340 341 351 352 374 375 400 404 405 410 411 420 440 441 442 445 449 504 透鏡 反射器形狀 纖維 輸出連接器 輸出連接器 輸入連接器 基板 互連電路層 纖維 纖維 車輛前燈 車輛前燈 光源 LED晶粒 黏性層 被動光學元件 微複製反射器薄片 反射器 基板 圖案化撓性電路層 電導體圖案 圖案化黏性層 準標 LED晶米4 O:\89\89766.DOC -37- 200423821 506 磷光體層 507 有角度表面 540 基板 541 電接觸表面 545 電線焊接 546 焊墊 O:\89\89766.DOC -38-
Claims (1)
- 200423821 拾、申請專利範園: 1 一種照明裝置,其包括: 複數用於產生光學輕射之固態轄射源(104),其較佳為 複數LED晶粒; 為忒專複數固悲輻射源提供電性連接的互連電路層 (142); 複數光學波導(122),其較佳為複數光纖,其中每個該’ 等複數光學波導包括-第1及—第二端,其中每個第. 一端與該等複數固態輻射源之一對應固態韓射源形成光籲 學互通;以及 光學το件(120)陣列,其中光學元件陣列的每個光學 元件設置於該光學料之-對應第—端與㈣應固態轄 射源之間。 2· —種照明裝置,其包括: 複數用於產生光學輻射之固態輻射源(1〇4),其較佳為 複數LED晶粒; 複數光學波導,其較佳為複數光纖(122),其中每個該# 等複數光學波導包括一第一端及一第二端,其中每個第. 一端與该等複數固態輻射源之一對應固態輻射源進行光 學互通;以及 複數非折射光學元件(120),其中該等複數光學元件之 每個光學7G件设置於一對應第一端與該對應固態輻射源 之間,以及其中每個非折射光學元件形狀設定成反射由 一對應固態輻射源發射至一對應光學波導的集中光。 O:\89\89766.DOC 200423821 3· —種照明裝置,其包括: 一基板(440); 一用於產生輻射的固態輻射源(404)陣列,其較佳為一 LED晶粒陣列,該陣列熱耦合至該基板; 一為固態輻射源陣列提供電性連接之圖案化互連電路 層(441),該圖案對應該陣列; 一將該互連層黏接至該基板的第一圖案化黏性層(4〇5) ,該圖案對應該陣列; 一形成於一薄板(411)内,以集合從固態輻射源陣列發 出的輻射之反射光學元件(41〇)陣列;以及 一將該薄板黏接至該互連層之第二圖案化黏性層(445)。 4.如申請專利範圍第⑷項之照明裝置,其中該等複數光 纖包含複數聚合物包覆石英纖維,各具有大約4〇〇至大約 10 0 0微米的一核心直徑。 5. 7. 如申請專利範圍第項之照明裝置,其中該等議 纖之第二端經捆束而成一單—群組以形成一單一光照明 源、或捆束成分離群組以形成分離光昭明源。 t申請專利範圍第卜2或3項之照明裝置,其中光學元辦 陣列包含一光學集中元件陣列。 Γ請專利範圍第1或2項之照”置,其中該等複㈣ 纖進一步包含複數光學聚隹 用以接收從該等光纖之㈣為纖維透鏡’ 學輕射聚f &出的光學㈣並將該夫 8. 如申請專利範圍第1或2項之照明裝 置,其中該等光學元 O:\89\89766.DOC -2 - 200423821 件包含形成於一多層光學膜内的一反射器陣列、或一開 放腔金屬反射器陣列。 9·如申請專利範圍第8項之照明裝置,其中該反射器陣列相 對於該等LED晶粒置放,以實質上保留每個該等複數lED 晶粒之一實體。 10·如申請專利範圍第1、2或3項之照明裝置,其中至少一個 LED晶粒之一表面塗有一磷光體層,其較佳為一磷光體負 載環氧樹脂,更佳者其塗佈之量足以至少部分將每個lEd 晶粒之該輸出轉換至另一波長,並且實質上保留每個 晶粒之一實體。 11·如申請專利範圍第!、2或3項之照明裝置,其中每個[ED 晶粒具有一寬度,且其中每個LED晶粒設置在該互連電路 層上,其設置處距全部相鄰之LED晶粒之距離大於其寬 度。 12. 如申請專利範圍第⑷項之照明裝置,其中每個LE〇晶粒 表面安裝於該互連電路層上或置於該互連電路層之一凹 陷孔徑上。 13. 如申請專利範圍第6項之照明裝置,其中一鱗光體層層壓 至光學集巾元件之料列的該頂部表面及該底部表面之 — 〇 14. 一種車輛前燈,其包括如申請專利範圍第卜2或3項之照 明裝置。 15. 如申請專利範圍第卜2或3項之照明裝置,其中該光學元 件陣列包含—反射器陣列,其中該陣列的每個反射器具 O:\89\89766.DOC 200423821 一孔及ώ孔,且其中每個LED晶粒之一發射表面間 隔於該入孔之下。 16. 如申請專利範圍第1或2項 第二複數LED晶粒; 之照明裝置,其進一步包括: 端與該等第二複數LED晶粒之一 ;以及 弟一衩數光纖,各具有第一 及第二端,其中每個第一 led晶粒進行光學互通 其中該光學元件陣列插於該等第一及第二複數光纖之 一對應第一端與該對應LED晶粒之間。 17.如申請專利範圍第16項之照明裝置,其中該等第二複數 光纖之第二端與該等第一龍光纖之第二端捆束在-起,當照射時形成一單一光照明源。 18·如申请專利範圍第16項之照明裝置,其中該等第一及第 一複數LED晶粒具有不同發射頻譜。 19.如申請專利範圍第16項之照明裝置,其中該等第一複數 及第二複數波導包含第一複數及第二複數光纖,其中該 等第一複數光纖之第二端捆束成一第一棒束,且其中該 等第二複數光纖之第二端捆束成一第二棒束,且其中該 第一棒束之輸出發射的一第一方向不同於該第二棒束之 輸出發射的一第二方向。 2〇·如申請專利範圍第16項之照明裝置,其進一步包括: 第三複數LED晶粒;以及 第二複數光纖,各具有第一及第二端,其中每個第一 端與該等第三複數LED晶粒之一LED晶粒進行光學互通。 O:\89\89766.DOC -4- 200423821 21. 22. 如申請專利範圍第21項之照明裝置,其中該等第一複數 、,曰曰粒發射紅色光,其中該等第二複數[奶晶粒發射藍 色光’以及其中該等第三複數LED晶粒發射綠色光。 ,申明專利勒i圍第1、2或3項之照明裝置,其中該LED晶 李陣列的一輪出發射在一選擇色溫上產生光。 O:\89\89766.DOC
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-
2003
- 2003-12-02 CN CNB200380109097XA patent/CN100383573C/zh not_active Expired - Fee Related
- 2003-12-02 KR KR1020057009884A patent/KR20050072152A/ko not_active Application Discontinuation
- 2003-12-02 EP EP03812466A patent/EP1567894A2/en not_active Withdrawn
- 2003-12-02 TW TW092133837A patent/TW200423821A/zh unknown
- 2003-12-02 MX MXPA05005658A patent/MXPA05005658A/es not_active Application Discontinuation
- 2003-12-02 US US10/726,222 patent/US7163327B2/en not_active Expired - Fee Related
- 2003-12-02 WO PCT/US2003/038040 patent/WO2004051705A2/en not_active Application Discontinuation
- 2003-12-02 AU AU2003297588A patent/AU2003297588A1/en not_active Abandoned
- 2003-12-02 JP JP2004557401A patent/JP2006508514A/ja not_active Withdrawn
-
2006
- 2006-12-29 US US11/618,403 patent/US7360924B2/en not_active Expired - Fee Related
-
2008
- 2008-03-12 US US12/046,815 patent/US7658526B2/en not_active Expired - Fee Related
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8979313B2 (en) | 2011-12-29 | 2015-03-17 | Industrial Technology Research Institute | Semiconductor light source device |
Also Published As
Publication number | Publication date |
---|---|
AU2003297588A1 (en) | 2004-06-23 |
US20090059614A1 (en) | 2009-03-05 |
US20040149998A1 (en) | 2004-08-05 |
WO2004051705A2 (en) | 2004-06-17 |
US20070103925A1 (en) | 2007-05-10 |
MXPA05005658A (es) | 2005-08-16 |
US7658526B2 (en) | 2010-02-09 |
CN1742217A (zh) | 2006-03-01 |
JP2006508514A (ja) | 2006-03-09 |
KR20050072152A (ko) | 2005-07-08 |
EP1567894A2 (en) | 2005-08-31 |
US7163327B2 (en) | 2007-01-16 |
CN100383573C (zh) | 2008-04-23 |
AU2003297588A8 (en) | 2004-06-23 |
WO2004051705A3 (en) | 2004-08-19 |
US7360924B2 (en) | 2008-04-22 |
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