TW201144699A - High efficacy LED lamp with remote phosphor and diffuser configuration - Google Patents

Abstract

Solid state lamps and bulbs comprising different combinations and arrangements of a light source, wavelength conversion elements with one or more distinct phosphor layers or regions which are positioned separately or remotely with respect to the light source, and a diffuser element are provided. These elements may be arranged on or in conjunction with a thermal management device that allows for the fabrication of lamps and bulbs that are efficient, reliable and cost effective and can provide an essentially omni-directional emission pattern (even with a light source comprised of a co-planar arrangement of lighting devices such as LEDs). Various embodiments of the invention may be used to address many of the difficulties associated with utilizing efficient solid state light sources such as LEDs in the fabrication of lamps or bulbs suitable for direct replacement of traditional incandescent bulbs. Embodiments of the invention can be arranged to fit recognized standard size profiles such as those ascribed to commonly used lamps such as incandescent light bulbs, while still providing emission patterns that comply with ENERGY STAR ® standards.

Description

201144699 VI. Description of the Invention: Technical Field of the Invention The present invention relates to solid state lamps and light bulbs, and more particularly to efficient and reliable LEDs and bulbs capable of producing omnidirectional emission patterns. The present application claims the following claims: US Provisional Patent Application No. 61/339,516, filed March 3, 2010, and US Provisional Patent Application No. 61/ filed March 3, 2010 U.S. Provisional Patent Application No. 61/386, 437, No. 61/424, 665, filed on September 24, 2012 U.S. Provisional Patent Application No. 61/424, No. 61, No. 61/434, 355, 曰 凊 凊 12 12 12 12 12 12 12 12 12 12 12 12 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国 美国U.S. Provisional Patent Application No. 61/435,326, filed on Jan. 23, the entire disclosure of which is hereby incorporated by reference. This application is also part of the following applications and claims its rights: U.S. Patent Application No. 12/848,825, filed on August 2, 2010, September 24, 2010 U.S. Patent Application Serial No. 12/975,82, filed on Jan. 22, s. [Prior Art] Incandescent or light bulbs or filament-based lamps or bulbs are commonly used as household appliances. These lamps are extremely inefficient.

154499.doc and light source for commercial facilities. However, this source is in the form of up to 95% of the input energy loss. One of the Incandescent Lamps 7 201144699 Materials 'These toxic materials and their various compounds can cause chronic and acute poisoning and can cause environmental pollution. One solution for improving the efficiency of a lamp or bulb is to use a solid state device, such as a light emitting diode (LED), rather than a metal filament, to produce light. The light emitting diode typically comprises a layer of opposite doping type. One or more active layers of semiconductor material. When a bias voltage is applied to the doped layers, holes and electrons are injected into the active layer where they recombine to produce light. The light system acts on the active layer and is emitted from each surface of the LED. In order to use led wafers in circuits or other similar configurations, it is known to enclose a led wafer in a package to provide environmental and/or mechanical protection 'color selection, light focusing, and the like. The LED package also includes electrical leads, contacts or traces for electrically connecting the LED package to an external circuit. In a typical led package 10 illustrated in Figure 1, a single LED wafer 12 is mounted to a reflective cup 13 by means of a solder bond or a conductive epoxy tree. One or more wire bonds 11 connect the ohmic contacts of the LED wafer 12 to wires 15A and/or 15B, which may be attached to or integral with the reflective cup 13. The reflector cup can be filled with an encapsulant material 16'. The encapsulant material 16 can contain a wavelength converting material such as a phosphor. Light emitted by the LED at the first wavelength can be absorbed by the phosphor, which responsively emits light at the second wavelength. The entire assembly is then encapsulated in a clear protective resin 14 which can be molded into a lens shape to collimate light emitted from the LED wafer 12. 2 shows another embodiment of a conventional LED package that includes one or more LED wafers 22 mounted to a carrier, such as a printed circuit board (PCB) carrier, substrate or submount 23. Metal reflector 24 mounted on submount 23 154499.doc 201144699 surrounds (equal) LED wafer 22 and reflects light emitted by LED wafer 22 to move light away from package 20. The reflector 24 also provides mechanical protection of the LED wafer 22. One or more wire bond connectors 27 are formed between the ohmic contacts on the LED wafer 22 and the electrical traces 25A, 25B on the submount 23. The mounted LED wafer 22 is then covered with an encapsulant 26 which provides environmental and mechanical protection to the wafer while also acting as a lens. Metal reflector 24 is typically attached to the carrier by means of solder or epoxy bonding. LED wafers (such as the LED chips found in LED package 20 of Figure 2) can be coated by a conversion material comprising one or more phosphors, wherein the phosphors absorb at least some of the LED light. The LED wafer can emit light of different wavelengths such that it emits a combination of light from the LED and the phosphor. LED wafers can be coated with phosphors in a number of different ways, one suitable method of which is described in U.S. Patent Application Serial No. 11/656,759, the entire disclosure of The title is "Wafer Level Phosphor Coating Method and Devices Fabricated Utilizing Method." Alternatively, other methods such as electrophoretic deposition (EPD) can be used to coat the LEDs, a suitable EPD method is described in U.S. Patent Application Serial No. 11/473,089, to No. Lamps utilizing solid state light sources (such as LEDs) incorporating a conversion material have also been developed that are separate from or located at the distal end of the LED. Such a configuration is disclosed in U.S. Patent No. 154,499, doc to No. 154,499, the entire disclosure of which is incorporated herein by reference. The lamp described in this patent can include a solid state light source that transmits light through a splitter to a disperser having a phosphor. The disperser can disperse the light in a desired pattern and/or change the color of the light by converting at least some of the light to a different wavelength via a phosphor or other conversion material. In some embodiments, the separator separates the source from the disperser a sufficient distance such that when the source carries the elevated current necessary for illumination in the room, heat from the source will not be transferred to the disperser. An additional remote phosphor technique is described in U.S. Patent No. 7,614,759, the entire disclosure of which is incorporated herein by reference. One potential disadvantage of having a remote phosphor lamp is that the volume of the desired phosphor can be ~i (9) times the volume of the conformal or adjacent phosphor g&amp; The filling of the material can be compared with Aobe, and the increase in the amount of phosphor required for remote applications is such that the 4-light body becomes a major factor in the increase in the driving cost of the LED lamp product. In addition, the supply of certain phosphor types may be limited and/or difficult to increase in the near future to meet the needs of remote phosphor applications. In addition, the heat generated in the phosphor layer during the conversion process can be constrained by insufficient heat conduction heat dissipation compared to conformal or adjacent phosphor configurations that are conducted or dissipated through the nearby wafer or substrate surface. Scatter path. In the absence of an effective heat dissipation path, the thermally isolated remote disc can be raised to the operating temperature, and the operating temperature of the S can be even comparable to the conformal conformation in some examples. The temperature in the coating layer. This situation can be met by some or all of the benefits achieved by placing the phosphor at the distal end relative to the wafer. In other words, the distal phosphor placement of the LED wafer can reduce or (d) the direct heat generation of the 154499.doc 201144699 phosphor layer due to the heat generated in the wafer during operation, but the resulting phosphor temperature is reduced. The small amount may be partially or fully attributed to the heat generated in the phosphor layer itself during the light conversion process and the lack of a suitable thermal path to dissipate the heat generated thereby. Another problem affecting the implementation and acceptance of lamps utilizing solid state light sources is related to the nature of the light emitted by the source itself. Angle uniformity (also known as luminous intensity distribution) is also important for solid state light sources that will replace standard incandescent bulbs. The geometric shape relationship between the filament of a standard incandescent bulb and the glass bulb shell, combined with the fact that no electronic components or fins are required, allows light from a white woven bulb to illuminate in a relatively omnidirectional pattern. That is, the luminous intensity of the bulb is vertical; t is distributed relatively uniformly across the angle from the top of the bulb to the threaded base in the vertical plane of the bulb, and only the base itself causes significant light obstruction. In order to manufacture a lamp or bulb based on the efficiency of the LED source (and associated conversion layer), it is often desirable to place the LED wafer or package in a coplanar configuration. This facilitates manufacturing and reduces manufacturing costs by allowing the production equipment and processes to be known. However, the coplanar configuration of the LED wafer typically produces a forward light 5 goldens profile (e.g., 'Lambertian profile'). Such beam profiles are generally undesirable in applications where solid state lamps or lamps are intended to replace conventional lamps, such as &apos;conventional incandescent bulbs, which have a more omnidirectional beam pattern. Although it is possible to mount a led light source or package in a two-dimensional configuration, it is often difficult and expensive to fabricate such configurations. Solid state light sources also typically include electronic circuits and heat sinks that may block light in some directions. SUMMARY OF THE INVENTION In a particular embodiment, the present invention is based on the use of a solid state light source 154499.doc 201144699 month single 兀 '3 solid 26 source complying with the standard lighting unit (such as A" incandescent or The shape and size of the fluorescent light source, these solid-state light sources provide specific improved performance characteristics for such illumination units (such as complying with ENERGY STAR 9). These lighting units can be used by using solid state light sources ( A combination of various combinations of, for example, a light-emitting body, a wavelength converting material (such as a light body), a diffuser element, and a thermal management system, system/component. In a particular embodiment, the solid state light source comprises Transducing at least one light of at least one first wavelength, the photodiode. The wavelength converting material comprises a reverse wavelength converting element above the solid state light source. The wavelength converting element may comprise at least one light filling body | The dish interacts with the at least one wavelength of light to produce at least a second wavelength of light. The diffuser element is located at the distal end of the wavelength conversion element and is used to produce a more uniform light emission In a particular implementation, the present invention provides a lamp and a light bulb that generally comprise: different combinations and configurations of each: a light source, one or more wavelength converting materials, separately positioned relative to the light source, or positioned at a distal end a region or layer, and a separate diffusion layer. This configuration allows for the manufacture of efficient and reliable lamps and bulbs, and can provide a substantially omnidirectional emission pattern. Various embodiments of the present invention can be used to address the direct replacement of traditional incandescent in manufacturing. It is difficult to relate to the use of efficient solid state light sources, such as LEDs, during the lamp or lamp of the bulb. Embodiments of the invention may be configured to accommodate a recognized profile of the size, whereby Promoting direct replacement of such light bulbs. One embodiment of the illumination device according to the present invention comprises a solid state light source and a continuum element and a wavelength conversion element. The diffuser element is spaced apart from the light source. The wavelength conversion element is also associated with the light source The diffuser element spacing 154499.doc 201144699 is 'and includes one or more dissimilar phosphor layers for converting the (equal) wavelength of light emitted from the source. Another embodiment of the illumination device according to the present invention includes a solid state light source, a diffuser element, and a wavelength converting element. The diffuser element is disposed over the light source. The wavelength converting element is also disposed over the light source. The wavelength conversion element further includes one or more dissimilar phosphor layers for converting the (equal) wavelength of light emitted from the source. One embodiment of the solid state lamp according to the present invention comprises a solid state light source, a diffuser element, and a wavelength conversion element. The diffuser element is located above and spaced apart from the light source. The wavelength conversion element is located above and spaced apart from the light source and over the diffuser element and with the diffuser element The wavelength conversion element includes one or more distinct scale layers for converting the (4) wavelength of light emitted from the source. The diffuser element and the wavelength conversion element provide a dual sphere structure. Another embodiment of a solid state light in accordance with the present invention comprises a solid state light source - a diffuser element and a wavelength converting element. The diffuser element is located above and spaced apart from the light source. The wavelength conversion element is positioned above the source and spaced apart from the 玄 source, wherein the wavelength conversion element includes one or more dissimilar phosphor layers for converting the (equal) wavelength of light emitted from the source. The diffuser element is positioned above and spaced apart from the wavelength converting element, and the diffuser element and the wavelength converting element provide a dual sphere structure. These and other aspects and advantages of the present invention will become apparent from the following detailed description and appended claims <RTIgt; </RTI> <RTIgt; </ RTI> <RTIgt; The present invention is described herein with reference to the particular embodiments thereof, but it is understood that the invention may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. The present invention is directed to different embodiments of an efficient, reliable, and cost effective lamp or bulb structure. In some embodiments, the lamps or bulb structures can provide a substantially omnidirectional emission pattern from a directional emission source, such as a forward emitting source. Moreover, in some embodiments of the invention, the lamp or bulb structure utilizes a solid state illuminator having a distal light converting material and a distal diffusing element. Additionally, in some embodiments, the conversion material can comprise one or more distinct layers of a single or multiple phosphors, wherein the order and number of phosphor layers can vary and depend on the desired emission characteristics of the device and the type of source/ The color and type/color of the phosphor used. The phosphor layers may or may not be located at the distal end of the source. In some embodiments, the diffuser disperses or redistributes light from the source of the distal phosphor and/or lamp into a desired emission pattern. In some embodiments, the diffuser spheres can be configured to disperse the forward emitting pattern into a more omnidirectional pattern that can be used in general lighting applications. Some embodiments of a lamp in accordance with the present invention can have a conversion material over the source and spaced apart from the source. A diffuser spaced from the conversion material may also be included to cause the lamp to exhibit a dual sphere structure. The space between the various structures may include light mixing chambers that not only promote dispersion of lamp emissions but also promote color uniformity of lamp emission. The space between the light source and the conversion material or diffuser and the space between the conversion material and the diffuser 154499.doc 201144699 Can act as a light mixing chamber. Other embodiments may include additional conversion materials or diffusers that may form additional mixing chambers. The order of the conversion material and the diffuser can be varied such that some embodiments can have a diffuser inside the conversion material with the space therebetween forming a light mixing chamber. These configurations are only a few of the many different conversion materials and diffuser configurations in accordance with the present invention. Some lamp embodiments in accordance with the present invention may comprise a light source having a coplanar configuration of one or more lED wafers or packages, wherein the illuminators are mounted on a flat or planar surface. In other embodiments, the LED wafers may not be coplanar, such as attached to a pedestal or other three dimensional structure. Coplanar light sources reduce the complexity of the illuminator configuration, making it easier and less expensive to manufacture. However, coplanar light sources tend to illuminate primarily in the forward direction, such as in a Lambertian emission pattern. In various embodiments, it may be desirable to emit a light pattern that mimics the light pattern of a conventional incandescent light bulb, which is known to provide nearly uniform emission intensity and color uniformity at different emission angles. Different embodiments of the present invention can include features that can transform the emission pattern from non-uniform to substantially uniform over a range of viewing angles. In some embodiments, a transition region can comprise a material that is at least partially transparent to light from the source and at least one layer of phosphor material that absorbs light from the source and emits light of a different wavelength. The diffuser can comprise a diffusing film/particle and an associated carrier (such as a glass envelope) and can be used to scatter or redirect at least some of the light emitted by the source and/or phosphor layer to provide a desired beam profile. The properties of the diffuser, such as geometry, scattering properties of the scattering layer, surface roughness or smoothness, and the spatial distribution of the properties of the scattering layers, can be used to control various lamp properties, such as 154499.doc depending on the viewing angle. •12· 201144699 Color uniformity and light intensity distribution. By illuminating the 先 敝 先 先 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及 及A heat sink structure can also be included. The heat sink structure can be in thermal contact with the light source, the fill layer, and/or the diffuser and other light elements to dissipate heat to the surrounding environment t. Electronic circuitry may also be included to provide power to the light source and provide other capabilities (such as dimming, etc.), and such circuitry may include components (such as a screw mount, etc.) to apply electrical power to the light. Different embodiments of the lamp can have many different shapes and sizes, some of which have dimensions that can be mounted into a standard size bulb housing such as the A19 size bulb housing 30 as shown in FIG. This makes the lamp particularly useful as an alternative to conventional incandescent lamps or bulbs and fluorescent lamps or bulbs, wherein the lamp according to the present invention enjoys reduced energy consumption and long service life provided by its solid state light source. Lamps in accordance with the present invention may also accommodate other types of standard size profiles including, but not limited to, A21 and A23. In some embodiments, the light source can comprise a solid state light source, such as a different type of LED, LED wafer, or LED package. In some embodiments, a single LED wafer or package can be used, while in other embodiments, multiple [ED wafers or packages can be configured in different types of arrays. By having good heat dissipation and • thermally isolating the phosphor layer from the LED wafer, the LED wafer can be driven by a higher current level without detrimental effects on the conversion efficiency and long-term reliability of the phosphor layer. This allows for the flexibility of energizing the LED wafers in the afternoon to reduce the number of LEDs required to produce the desired luminous flux. This in turn reduces the cost of the complexity of the lamp. Such LED packages may include LEDs that are encapsulated by materials that can withstand elevated luminous fluxes 154499.doc • 13· 201144699 or may include unencapsulated LEDs. Some of the LED lamps in accordance with the present invention may have a correlated color temperature (CCT) from about 12 〇〇 K to 3500 K and other LED lamps may emit light having a distribution of the following illuminating intensity from the top of the lamp: between 0 〇 and 15 。. The variation within the range is not more than 10 ° /. . In other embodiments, the lamp can emit light having the following luminous intensity distribution at 0. The variation within the range of 135° is not more than 2%. In some embodiments, at least 5% of the total flux from the lamp is at 135. To 180. In the district. Other embodiments may emit light having the following luminous intensity distribution: at 〇. The change within the range of 丨2〇〇 is not more than 30%. In some embodiments, the LED luminaire has a color space uniformity such that the chromaticity changes by no more than 0.004 with respect to the weighted average point as the viewing angle changes. Other lamps can meet the luminous efficacy and color of the 6 watt wattless replacement bulb. Operational requirements for spatial uniformity, light distribution, color rendering index, size, and base type. As described in more detail below, LED lamps in accordance with the present invention can have many different types of illuminators that emit light of different wavelength spectra. In some embodiments the illumination unit in accordance with the principles of the present invention emits at least three peak wavelengths of light (e.g., blue, yellow, and red). At least a first wavelength is emitted by a solid state light source (such as blue light) and at least a second wavelength is emitted by a wavelength conversion element (such as &apos;green light and/or yellow light). Depending on the embodiment, a third wavelength of light, such as &apos;green and/or red, may be emitted by the solid state light source and/or wavelength conversion element. In some embodiments, the at least three wavelengths can be emitted by a wavelength converting element or a solid state light source. In some embodiments, the solid state light source can emit light of overlapping, similar or identical wavelengths to the wavelength converting material. For example, a solid state light source can include an emission that overlaps or is emitted by light emitted by a layer of light 154499.doc -14- 201144699 in a wavelength converting material (eg, a red phosphor added to a yellow phosphor in a wavelength converting material). An LED that emits light of the same wavelength (for example, red light). In some embodiments, the solid state light source comprises at least one additional LED that emits light having at least one different peak light wavelength, and/or the wavelength converting material comprises at least one additional light body that emits at least one different peak wavelength. Thus, the illumination unit emits light having at least four different peak light wavelengths. Depending on the embodiment, the solid state light source can comprise a single string or multiple strings of LEDs. The wavelength converting element can include a scale layer disposed as a distinct wavelength converting element on the solid state light source and/or located at the distal end of the solid state light source. A lighting unit using a wavelength converting material applied to individual LEDs in a solid state light source is described in the following application: U.S. Patent Application Serial No. 12/ entitled "LED Lamp with High Color Rendering Index" by van de Ven et al. 975,82, the application of which is incorporated herein by reference. The wavelength converting element can comprise a phosphor layer embedded on or integral with the inner surface and/or the outer surface of the conversion element and/or embedded with the conversion element. The diffuser element can include diffuser particles coated on the inner and/or outer surface of the diffuser and/or embedded in or integral with the diffuser. In some embodiments, the diffuser contains structures or features such as rubbing or roughing. In some embodiments of the invention, the LED assembly includes an LED package that emits blue light and other LED packages that emit red light. In some embodiments, the LED assembly of the LED lamp includes an LED array having at least two LED groups, wherein one group will emit a 154499.doc -15-201144699 dominant wavelength having 44 〇nmi 48 〇 nm when illuminated. Light, and another group will emit light having a dominant wavelength of 605 nm to 63 nm when illuminated. The phosphor can be configured to absorb light from one or both of the two wavelength spectra and re-emit light, and the fill may have one or more distinct phosphor layers comprising a single or mixed phosphor type, Each of the one or more phosphor layers can absorb light and re-emit light of different wavelengths. Some lamp embodiments can include a plurality of LEDs that emit blue and red light, wherein the wavelength converting element comprises a yellow phosphor that absorbs blue light and re-emits yellow or green light, wherein one portion of the blue light passes through the phosphor layer. The red light from the (equal) red LED passes through the yellow/green scale while undergoing little or no absorption&apos; to cause the lamp to emit a combination of white light of blue, yellow/green and red light. In still other embodiments, blue and red LEDs can be provided where the phosphor layer comprises a yellow/green phosphor and a red phosphor to aid in the red component of the illumination and to assist in dispersing the LED light. In some embodiments, the LEDs can comprise two groups, with one LED group interconnected in a first_link and another led group interconnected in a second serial string. This situation is only one of many ways in which the LEDs can be interconnected, and it should be understood that the LEDs can be configured in many different combinations of parallel and series interconnections. In some embodiments, a lamp according to the present invention can emit light having a high color rendering index (CRI) such as 8 〇 or higher. In some other embodiments the 'lights can emit light having a CRI of 90 or higher. The lamp can also produce light with a correlated color temperature (CCT) from 2500 K to 3500 K. In other embodiments, the light may have a CCT from 2700 K to 3300 K. In still other embodiments, the light may have a CCT from about 2725 K to about 3045 K. In one embodiment 154499.doc -16- 201144699, the light may have a CCT of about 2700 K or about 3000 K. In still other embodiments of light tunable, the CCT can be reduced by dimming. In this case, the CCT can be reduced to as low as 1500 K or even as high as 1200 K. In some embodiments, the CCT can be increased by dimming. Depending on the embodiment, other output spectral characteristics can be varied based on dimming. It should be noted that other configurations of LEDs can be used with embodiments of the present invention. The same number of LEDs of each type can be used, and the LED package can be configured with varying patterns. A single LED of each type can be used. Additional LEDs that produce extra color light can be used. The CRI of the illumination unit can be increased by using a wavelength conversion element&apos; that emits one or more additional colors or multiple LEDs and/or one or more additional phosphors or phosphor layers. Luminescent materials can be used with all LED modules. A single luminescent material can be used with multiple LED dies and multiple LED dies can be included in one, some, or all of the LED device packages. A more detailed example of the use of a group of LEDs that emit light of different wavelengths to produce substantially white light can be found in the issued U.S. Patent No. 7,213,940, the disclosure of which is incorporated herein by reference. Some lamp embodiments in accordance with the present invention can include a first solid state illuminator group and a first luminescent material group ' wherein the first luminescent material group includes at least one luminescent material. The lamps also include a second group of solid state illuminators, wherein the second group of solid state illuminators includes at least one solid state illuminator and at least one first power line. Each solid state illuminator in the first set of solid state illuminators and each of the first solid state illuminator groups can be electrically connected to the first power line. Each of the solid state illuminators in the first set of solid state illuminators emits 154499.doc -17-201144699 light having a dominant wavelength in the range of 430 nm to 480 nm when illuminated. Each of the first luminescent material groups, when excited, emits light having a dominant wavelength in the range of from about 555 nm to about 585 nm. Each of the solid state illuminators in the second set of solid state illuminators emits light having a dominant wavelength in the range of 600 nm to 630 nm when illuminated. If a current is applied to the first power line, in the absence of any additional light, the combination of the following will produce a mixture of light having a y, y coordinate on the 1931 CIE chromaticity diagram: (1) from the first solid state Light emitted by the illuminator group leaving the illumination device, (2) light emitted by the first illuminant group exiting the illumination device, and (3) emitted from the second solid state illuminator group leaving the illumination device Light. The coordinates define a point that lies within ten MacAdam ellipses of at least one point on the black body locus on the 193 丨 ciE chromaticity diagram. This combination of light also produces a sub-mixture of light having X,y color coordinates that define a point at the first, second, and third points on the 193 CIE chromaticity diagram. The fourth, third, fourth and fifth connecting line segments defined by the fourth point and the fifth point are enclosed in the area. The first point may have an X, y coordinate of 0.32, 〇 _40, the second point may have x, y coordinates 〇 36, 0.48, the third point may have a 丫 coordinate 〇 43 〇 45, and the fourth point may have a 乂 ^ coordinate 0.42, 0.42, and the fifth point may have χ, y coordinate 〇%, 〇38. The present invention also provides LED lamps having features of relative geometries, such as LE〇 heat dissipating devices or heat sinks, which feature features that allow the lamp emission pattern to be met in a manner that is ENERGY STAR® Program Requiremems ^, as amended on March 22nd

LampS)" requirements. These relative geometries allow light to be at zero. To 135. 154499.doc -18· 201144699 The average value is dispersed within 20%, while the total luminous flux is greater than 5% at i35. To 180. In the zone (in 〇., 45. and 9〇. Measurement under azimuth). The relative geometry includes LED assembly mounting width, height, heat dissipation device width, and a unique downward chamfer angle. Combining the spherical wavelength conversion elements and/or the reflector and diffuser domes in accordance with the present invention, these geometries will allow light to be dispersed according to such stringent ENERGY STAR requirements. The present invention can reduce the surface area required to dissipate heat from LEDs and power electronics, and still allow the lamp to follow the ANSI A^9 lamp profile. The present invention also provides a lamp with enhanced emission efficiency, wherein some of the lamps according to the present invention Emitted at 65 lumens per watt (LPW) or more than 65 lumens per watt. In other embodiments, the lamp can illuminate at an efficiency of 8 〇 LPW or more than 80 LPW. In all such embodiments, the lamp can emit a more desirable color temperature (eg, 3000 K or less, or in some embodiments, 2700 K or less) and a more desirable color rendering index ( For example, 90 or more CRI light than 90. Some lamp embodiments in accordance with the present invention can emit 7 lumens or more than 7 lumens of light, while other lamp embodiments can emit 750 lumens or greater than 750 lumens of light. Still other lamp embodiments can emit 800 lumens or greater than 8 lumens, with some of these lamp embodiments emitting this light at 1 watt or less. These emissions provide the desired brightness while providing the additional advantage of being able to pass a less stringent regulation (eg, ENERGY STAR®) for lamps operating at less than 10 W. This can lead to faster introductions. The light of the market. This emission efficiency can be the result of many factors, such as: the maximum surface area of the thermal system, the most 154499.doc that causes the minimum amount of light to be blocked, and the use of remote conversion components. The distal conversion element can result in higher performance (8 〇 lumens per watt or greater than 80 lumens per watt) than an illuminator having a conformally coated conversion material (although some embodiments can include wavelength conversion elements with conformal coating) Illuminator). Thus, embodiments of lighting units in accordance with aspects of the present invention can be used to provide LED-based replacement A-lamps for standard incandescent 60 watt incandescent bulbs that meet the ENERGY STAR 8 performance requirements. Other embodiments may provide an LED replacement A-lighting unit with a higher wattage incandescent bulb, such as a standard 75 watt or 1 watt wattled AI9 bulb. In other embodiments, the shai lighting unit can replace the standard 4 watt incandescent a 19 bulb. Other embodiments of the lighting unit in accordance with aspects of the present invention can be used to replace other standard shaped incandescent or fluorescent lamps. Different lamp embodiments may also include components configured to cause the lamp to exhibit a relatively long life. In some embodiments, the lifetime may be 25 hours or more than 25,000 hours, while in other embodiments, the lifetime may be 4 hours or more, more than 40,000 hours. In still other embodiments, the lifetime may be 50,000 hours or 5 inches, more than one hour. Such extended life may be at operating efficiencies of, for example, 80 lumens per watt or 80 lumens per watt and may be at different temperatures (such as 25t and/or 45t). This life can be measured in a number of different ways. The first method can simply operate the lamps over their lifetime until the lamps fail. However, this situation can often require an extended period of time, making this method impractical in certain situations. Another acceptable method is: # Calculate the lamp life from the life of each component used in the lamp. This information is often provided by the manufacturer 154499.doc •20· 201144699 and often lists operational life. It can then be followed by operating conditions such as temperature. The third method of accessibility uses this data to calculate the life of the lamp, such as higher temperature or rise. Hunting is caused by the operation of the lamp under the condition of the sublimation (the I^ power or switching signal). An earlier lamp failure is then used in accordance with known methods to determine the operational life of the lamp under normal operating conditions. The same embodiment may also include security features that are exposed to the absence of specific electrical features or components that rupture in either or both of the diffuser ball conversion element spheres. This special security feature reduces and/or eliminates the risk of electric shock due to contact with such electrical features, and in some embodiments, such security features may include different configurations of electrically insulating materials that cover the electrical features. The present invention provides a unique combination of features and characteristics that allow for long life and efficient operation in a simple and relatively inexpensive configuration. The lamp can be operated with a lumen/watt or greater than 80 lumens/watt performance while still producing 8 turns and CRs above 80 or 90 and above 90. In some embodiments, the performance can be: less than 10 watts to achieve this The situation can be provided in the following lamps: LEDs with their light source and dual dome diffuser and conversion material configuration, while still installed in the A19 size bulb housing and emitting a uniform light distribution according to Energy Star 8 requirements . A lamp having this configuration can also emit light having a temperature of 3 〇〇〇 K and 3 〇〇〇 K or 2700 K or less. The invention is described herein with reference to a particular embodiment, but it is understood that the invention may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. In particular, the invention is described below with respect to specific lamps having different configurations - 154499.doc • 2J·201144699 or more LED or LED wafers or LeD packages, but it should be understood that the invention can be used with many Many other lights of different configurations. An example of a different lamp that is configured in a different manner in accordance with the present invention is described in the following and is described in U.S. Provisional Patent Application Serial No. 61/435,759, the entire disclosure of which is incorporated herein by reference. Application, January 24, 2011, and incorporated herein by reference. The following examples are described with reference to one or more LEDs, but it should be understood that this scenario is intended to cover LED wafers and LED packages. The components can have different shapes and sizes other than the shapes and sizes shown, and can include a different number of LEDs. It should also be understood that the embodiments described below utilize coplanar light sources 'but it should be understood' that non-coplanar light sources can also be used. It should also be understood that the LED light source of the lamp can include one or more LEDs, and in embodiments having more than one LED, the LEDs can have different emission wavelengths. Similarly, some LEDs may have phosphor layers or zones adjacent or in contact, while other LEDs may have adjacent phosphor layers of different compositions or no phosphor layers at all. The invention is described herein with reference to conversion materials, wavelength converting materials, remote fills, phosphors, phosphor layers, and related terms. The use of such terms should not be construed as limiting. It should be understood that the use of the terms "distal disc", "disc" or "phosphor layer" is intended to cover all wavelength converting materials and is equally applicable to all wavelength converting materials. Some of the embodiments described herein include a distal phosphor and a single distal diffuser configuration&apos; some of which are in the form of a double sphere/154499.doc-22-201144699 dome. It should be understood that in other embodiments, there may be a single dome-like structure having both conversion and diffusion properties, or there may be more than two circles $ having different combinations of conversion material and diffuser. The conversion material and diffuser can be provided in the respective spheres/dome, or the conversion material and the diffuser can be together on one or more of the spheres/dome. The term "long body or dome" should not be construed as being limited to any particular shape. The term can encompass many different three-dimensional shapes including, but not limited to, bullet, spherical, tubular/slender, or flattened configurations. The invention is described herein with reference to conversion materials, phosphor layers, and diffusers located at the distal ends of each other. In this context, the distal ends are spaced apart from each other and/or are not in direct thermal contact. It will be further understood that when discussing the dominant wavelength, there is a range or width of wavelengths around the dominant wavelength such that when discussing the dominant wavelength, the invention is intended to cover a range of wavelengths around the wavelength. It is also understood that when an element such as a layer, a layer or a substrate is referred to as being "on" another element, it can be directly on the other element or the intervening element can also be present. In addition, terms such as "inside", "outside", "upper", "above", "below" and "below" are used herein to describe the relationship of one layer or another. It is to be understood that the terms are intended to encompass the orientations depicted in the drawings and the various aspects of the embodiments. Although the terms first, second, etc. may be used to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections are not to be limit. The terms are only used to distinguish one element, component, region, layer or section from another. Thus, the first element, component, region, layer or section discussed below may be referred to as a second element, component, region, layer or layer, without departing from the teachings of the present invention. Sections herein are described with reference to cross-sectional illustrations of schematic illustrations of embodiments of the invention. Because of %, the actual thickness of the layers can be different and it is expected that there will be differences in shape relative to the moon due to, for example, manufacturing techniques and/or tolerances. The embodiments of the invention should not be construed as being limited to the particular shapes of the regions described herein, but will include variations in the shape resulting from, for example, manufacture. Areas that are described or described as square or rectangular will generally have the characteristics of rounding or squeaking due to positive tolerances. The area illustrated in the figures is, therefore, in the nature of the invention, and is not intended to limit the scope of the invention. 4 shows an embodiment of a lamp 5A according to the present invention comprising a heat sink structure 52 having an optical cavity 54 having a platform 56 for holding a light source 58. Although this and some embodiments are described below with reference to optical cavities, it should be understood that many other embodiments without optical cavities may be provided. Such embodiments may include, but are not limited to, a light source on a planar surface of the lamp structure or on a pedestal. Light source 58 can include a number of different illuminators, with the embodiment shown including an LED. Many different commercially available LED wafers or LED packages can be used including, but not limited to, LED wafers or LED packages available from Cree, Inc. of N〇rth Carolina, Durham. It will be appreciated that lamp embodiments without optical cavities may be provided in which the LEDs are mounted in different ways in these other embodiments. By way of example, the light source can be mounted to a flat surface in the lamp or a base for holding the LED can be provided. Light source 58 can be mounted to 154499.doc using a number of different known mounting methods and materials. • 24·201144699 Platform 56&apos; wherein light from source 58 is emitted from the top opening of cavity 54. In some embodiments, the light source 58 can be mounted directly to the platform %, while in other embodiments the light source can be included on a sub-substrate or printed circuit board (PCB), followed by the sub-substrate or printed circuit board (p (: Β) is mounted to the platform 56. The platform 56 and the heat sink structure 52 can include a heart to apply an electrical signal to: a conductive path of the source 58 where some of the electrical paths are conductive traces or wires. Portions may also be made of a thermally conductive material, and in some embodiments, heat generated during operation may be spread to the platform and then spread to the heat sink structure. The heat sink structure 52 may at least partially comprise a thermally conductive material and may use many different The thermally conductive material comprises a different metal (such as copper or aluminum) or a metal: gold. The copper may have a thermal conductivity of up to 400 W/mk or more than 400 W/mk. In some embodiments, the heat sink may comprise high purity. Aluminum, high purity aluminum may have a thermal conductivity of about 210 W/m_k at room temperature. In other embodiments, the fin structure may comprise die cast aluminum having a thermal conductivity of about 2 〇〇 W/mk. Structure 52 can also include such as heat sink fins Other heat dissipation features of the crucible that increase the surface area of the heat sink to promote more efficient dissipation into the environment. In some embodiments, the heat sink fins 6 may have a higher thermal conductivity than The remainder of the heat sink is made of material. In the illustrated embodiment, the fins 6' are shown in a generally horizontal orientation, although it should be understood that in other embodiments, the fins may have a vertical or angled orientation. In still other embodiments, the heat sink may include an active cooling element (such as a fan) to reduce convective thermal resistance within the lamp. In some embodiments, the heat dissipation of the self-converting element is dissipated via convection heat and via heat dissipation The combination of the conduction of the sheet structure 52 is 154, 499. doc, and is described in U.S. Patent Application Serial No. 61/339,516, the entire disclosure of which is incorporated herein by reference. 1 &lt;1) Lamp Incorporating Remote Phosphor with Heat Dissipation Features and Diffuser Element, the same assignee of the present invention is hereby incorporated by reference. Reflective layer 53 can also be included on heat sink structure 52, such as on the surface of optical cavity 54. Reflective layers around the source may be included in embodiments that do not have an optical cavity. In some embodiments, the surface may be coated with a material having a reflectance of about 75% or more of the visible wavelength of the light emitted by the light source 58 and/or the wavelength converting element, while in other implementations In one example, the material can have a reflectivity of about 85% or more for the light. In still other embodiments, the material can have a reflectivity of about 95% or more for the light. The heat sink structure 52 may also include features for connection to a power source, such as to a different electrical outlet. In some embodiments t, the heat sink structure may include features of the type for mounting in a conventional electrical socket. For example, the heat sink structure can include features for mounting to a standard threaded seat, which can include a threaded portion that can be screwed into the threaded seat. In other embodiments, the heat sink structure may comprise a standard plug and the electrical socket may be a standard socket, or the heat sink structure may comprise a GU24 base unit, or the heat sink structure may be a clip and the electrical socket may receive and hold the clip The socket (for example, as used in the Hado fluorescent lamp). This (4) is an option for the heat sink structure and the socket and can also be used to safely deliver electricity from the socket to the lamp 50. 154499.doc -26 201144699 The lamp according to the invention may comprise a power supply or power A conversion unit, the power supply or power conversion unit can include a driver to allow the bulb to: AC line voltage/current supply and provide source dimming capability. In some implementations, the power supply can be housed in a cavity/female in a lamp heat sink (not shown) and can include an off-line current LED driver using a non-isolated quasi-resonant flyback topology. The LED driver can be mounted in (d), and in some embodiments, the LED driver can comprise 25 cubic centimeters or less than 25 cubic centimeters: and in other embodiments, the LED driver can comprise (10) cubic centimeters or less. The volume of cubic centimeters, and in still other embodiments, the led drive may comprise 2Q cubic centimeters or less than 2 () cubic centimeters of volume. In some embodiments, the power supply can be non-dimmable, but at a lower cost. It should be understood that the power supplies used may have different topologies or geometries&apos; and may also be dimmable #. Embodiments with (4) optics can exhibit many different dimming characteristics, such as dimming down to 5% (both front and back edges). In some dimming circuits in accordance with the present invention, dimming is achieved by reducing the output current to the LEDs. The power supply unit can include many different components that are configured on the printed circuit board in many different ways. The power supply can operate from many different power sources and can exhibit many different operational characteristics, in some embodiments, the power supply can be configured to operate from a 120 volt alternating current (VAC) ± 1 〇 % signal while providing greater than 200 Light source drive signal in milliamps (mA) and/or greater than 10 volts (v) "In other embodiments, the drive signal may be greater than 3 mA of generate power and/or greater than 15 volts. In some embodiments the 'drive signal' may be about 400 m A and/or about 2 2 V. 154499.doc •27- 201144699 ▲The power supply can also contain components that allow the power supply to be at a relatively high level. Efficiency - The measurement may be the actual input energy to the power supply as a percentage of the light output from the light source. A large amount of energy may be lost through the operation of the power supply. In some lamp embodiments, the power supply can operate at more than 1% of the wheel energy of the power supply as light radiation or output from the LED. In other embodiments, enter energy! More than 5% of the material is printed out. In still other embodiments, an input energy of about 17.5 〇 is used as the LED light output, and in other embodiments, about 18% or more of the input energy is used as the LEd light output. A thermal potting material may be included around the power supply or used for protection and to assist in the removal of thermal radiation from the power supply assembly. In embodiments where the power supply is in the heat sink cavity, the hot glue material may fill all or part of the cavity such that the hot glue material surrounds the power supply. Many different thermally conductive materials can be used that exhibit some or all of the following characteristics: safe, electrically insulating, conductive (four), have low thermal expansion, and have sufficient tack so that the material does not Cracks in the fin cavity leak out. Some embodiments may use an embedded compound comprising epoxy and glass fibers such as those available from Dow Corning, Inc. A wavelength conversion element 62 is included over the light source 58 and includes a diffuser element 76 over the conversion element 62. In the illustrated embodiment, conversion element 62 and diffuser element 76 are generally dome shaped. However, it should be understood that the elements are depicted for illustrative purposes only and are not limited to such specific shapes and/or configurations. It should be understood that the cavity opening (if there is a cavity opening), the diffusion 154499.doc • 28-201144699 and the conversion element can be of many different shapes and sizes. It should also be understood that the conversion element 62 may not cover the entire cavity opening. As further described below, the diffuser 76 is configured to disperse light from the conversion element 62 and/or the LED into a desired lamp emission pattern 'and can include many different shapes and sizes depending on the light it receives and the desired light emission pattern. The embodiment of the conversion element according to the invention may be characterized as comprising a different layer and/or zone of a conversion material, such as a 'phosphor, and a thermally conductive light transmissive material, but it is understood that 'a thermally non-conducting conversion element may also be provided . The light transmissive material may be transparent to light emitted from light source 58, and the (etc.) conversion material shall be of a type that absorbs light from the wavelength of the source and re-emits light of a different wavelength. In the illustrated embodiment, the thermally conductive light transmissive material comprises a carrier layer 64 and the conversion material comprises one or more dissimilar phosphor layers 66 on the carrier. As further described below, various embodiments may include many different configurations of thermally conductive light transmissive materials and conversion materials. When light from source 58 is absorbed by the phosphor in phosphor layer 66, the light is re-emitted in an isotropic direction, wherein about 鄕 of the light is emitted forward and 50% of the light is emitted back into cavity 54. And/or returning to the light source. In previous LEDs with a conformally coated phosphor layer, a significant portion of the back-emitting light can be directed back into the LED and the likelihood of light escaping is limited by the extraction efficiency of the coffee structure. For some LED's extraction efficiency may be about 7_, so a certain percentage of the light that is directed back into the LED from the conversion material may be lost. In a lamp having a configuration of a remote material according to the present invention, L 躁 is on the platform 56 at the bottom of the cavity 54, and a relatively souther percentage of light of the backward body light occupies the cavity and/or the platform. Surface instead of coffee. Pairs 154499.doc • 29. 201144699 These surface coatings add a percentage of light that is reflected back to the phosphor layer 66 (at the phosphor layer 66 where light can be emitted from the lamp) with a reflective layer 53. These reflective layers 53 allow the optical cavity to effectively recirculate photons&apos; and increase the emission efficiency of the lamp. It should be understood that the reflective layer can comprise a number of different materials and structures including, but not limited to, reflective metal or multilayer reflective structures such as distributed Bragg reflectors. In embodiments that do not have an optical cavity, a reflective layer around the LED can also be included. Carrier layer 64 may be made of many different materials having a thermal conductivity of 0.5 W/mk or more, such as quartz, tantalum carbide (SiC) (thermal conductivity ~120 W/mk), glass (thermal conductivity) The rate is 1.0-1.4 W/mk) or sapphire (thermal conductivity ~40 W/mk). In other embodiments, carrier layer 64 can have a thermal conductivity greater than 1.0 W/m-k, while in other embodiments it can have a thermal conductivity greater than 5.0 W/m-k. In still other embodiments, the carrier layer μ can have a thermal conductivity greater than 10 W/m-k. In some embodiments, the carrier layer can have a thermal conductivity in the range of from 1.4 W/m-k to 10 W/m-k. The barrier carrier can also have different thicknesses depending on the materials used, with suitable thicknesses ranging from 0.1 mm to 10 mm or more. It should be understood that other thicknesses may be used depending on the characteristics of the material used for the carrier layer. The material should be thick enough to provide adequate lateral heat dissipation for specific operating conditions. In general, the higher the thermal conductivity of the material, the thinner the material may be, while still providing the necessary heat dissipation. Different factors can influence which carrier layer material is used, and different factors include, but are not limited to, cost and transparency to the source light. Some materials may also be more suitable for larger diameters such as glass or quartz. By forming a phosphor layer on a larger diameter carrier layer and then singulating the carrier layer into 154499.doc • 30- 201144699 smaller carrier layer 'this material can provide reduced manufacturing costs ι in some In the examples, the carrier may comprise a polymer or plastic material, wherein the phosphor layer is applied to the inner and/or outer surface of the can carrier and/or embedded or mixed in the polymer or plastic. A number of different phosphors can be used in the phosphor layer 66, with the invention being particularly suitable for emitting white light lamps. As described above, in some embodiments, light source 58 can be LED-based and can emit light in the blue wavelength spectrum, but it should be understood that the LEDs can emit a wide range of colors and/or color combinations. Each phosphor layer can absorb some of the light emitted by the (etc.) LED. For example, the 'yellow phosphor layer can absorb some of the blue light emitted from the blue LED configuration' and re-emit yellow light. This situation allows the lamp to emit a combination of blue and yellow light. In some embodiments 'blue LED light can be converted by a yellow conversion material using a commercially available YAG:Ce phosphor, but using a system based on (Gd, Y) 3 (Al, Ga) 5012: Ce (such as Y3Al5〇) 12: Ce (YAG)) phosphor converted particles, it is possible to obtain a wide range of broad yellow spectral emission. Other yellow illuminators that can be used to produce white light when used with illuminators based on blue illuminating LEDs include, but are not limited to:

Tb3-xREx〇i2: Ce(TAG) , RE=Y, Gd, La, Lu; or Sr2.x-yBaxCaySi04:Eu. The conversion element can also be configured with more than one phosphor that is mixed in the phosphor layer 66 or as a second dissimilar phosphor layer on the carrier layer 64 or into the carrier layer 64. In some embodiments t, each of the two distinct phosphor layers can absorb LED light and can re-emit light of a different color. In such embodiments, the colors from the two phosphor layers can be combined to achieve a higher CRI white with different white tones using 154499.doc • 31·201144699 (warm white this case can include light red fluorescence) The light from the yellow phosphor in combination with the light of the body. Different red phosphors can be used, including:

SrxCai.xS: Eu, Υ, Υ == toothing;

CaSiAlN3:Eu; or Sr2-yCaySi〇4:Eu Other phosphors can be used to produce colored illumination by converting substantially all of the light into a particular color. For example, the following phosphors can be used to produce green light:

SrGa2S4: Eu;

Sr2-yBaySi〇4:Eu; or SrSi202N2:Eu » Some additional suitable phosphors that can be used as the conversion particles in the phosphor layer 66 are listed below, but other phosphors can be used. Each phosphor exhibits a blue and/or UV illuminating stimulus that provides a desired peak luminescence with efficient light conversion and an acceptable Stokes shift: yellow /Green (Sr,Ca,Ba)(Al,Ga)2S4:Eu2+

Ba2(Mg,Zn)Si2〇7:Eu2+

Gd〇 46Sr〇.3l A1i.2 3〇xF 1.3 8-Eu2 + 〇 〇6 (Baj.x.ySrxCay)Si〇4:Eu

Ba2Si04:Eu2+ Mu3 with Ce3Lu3A!5〇]2 154499.doc •32- 201144699 Doped Eu2+(Ca,Sr,Ba)Si202N2 CaSc2〇4:Ce3 + (Sr5Ba)2Si04:Eu2+ Red

Lu203:Eu3+ (Sr2_xLax)(Cei.xEux)〇4 Sr2Cei,xEux04 Sr2.xEuxCe〇4 SrTi03:Pr3 + ,Ga3 +

CaAlSiN3: Eu2+

Sr2Si5N8:Eu2+ may use phosphor particles of different sizes including, but not limited to, particles ranging from 1 nanometer (nm) to 30 micrometers (μm) or 30 micrometers (μm) or more. In terms of scattering and mixing colors, smaller particles are usually better than larger particles to provide a more even light. Larger particles are generally more efficient at converting light than smaller particles, but emit less uniform light. In some embodiments, the phosphor may be provided in the phosphor layer 66 in a binder, and the scale may also have a different concentration or loading of phosphor material in the binder. Typical concentrations range from 30% to 70% by weight. In an embodiment 10, the concentration of the optical body is about 65% by weight, and the block is uniformly dispersed throughout the distal scale. The smectic layer 66 can also have different zones with different conversion materials and conversion materials of different concentrations. The same material can be used for the adhesive, wherein the material is preferably strong after curing and substantially transparent in the visible wavelength spectrum. Suitable materials include Ju Shi Xi 154499.doc -33- 201144699 oxygen, epoxy resin, glass, inorganic glass, dielectric, BCB, polyamide, polymer and their blends, of which the preferred material is polyfluorene ( This is due to the high transparency and reliability of polyoxyl oxide in high-power LEDs. The base-based and methyl-based polyoxo oxygen can be purchased from Dow® Chemical. Different curing methods can be used to make bonding. Agent curing, depending on various factors such as the type of adhesive used. Different curing methods include, but are not limited to, thermal curing, ultraviolet (UV) curing, infrared (IR) curing, or air curing. In some embodiments The 'adhesive" may comprise a polymeric material or a plastic. The phosphor layer 66 may be applied using different processes including, but not limited to, spin coating 'sputtering, printing, powder coating, electrophoretic deposition (EpD), electrostatic deposition). And others. As mentioned above, the phosphor layer 66 can be coated with the binder material, but it should be understood that the binder is not required to be separately fabricated in another embodiment - the phosphor layer 66 can be separately fabricated and then The optical layer 66 is mounted to the carrier layer 64. In one embodiment, the phosphor-adhesive mixture can be sprayed or dispersed over the carrier layer 64. The adhesive is then cured to form the phosphor layer 66, in which embodiments In some embodiments of the tenth, the phosphor-binder mixture can be sprayed, poured or dispersed onto or onto the heated carrier layer 64 such that when the phosphor binder mixture contacts the carrier layer 64, from the carrier layer 64. The heat is dispersed into the binder and the binder is cured. These processes may also include a solvent in the spheroid-binder mixture which liquefies the mixture and reduces the viscosity of the mixture, thereby making the mixture more suitable for spraying Many different solvents can be used including, but not limited to, toluene, benzene, zylene or OS-20 available from Dow Corning®, and solvents of different concentrations of 154499.doc-34-201144699 can be used. When the solvent-phosphor-adhesive mixture is sprayed or dispersed on the heated carrier layer 64, the heat from the carrier layer 64 evaporates the solvent, wherein the temperature of the carrier layer affects the evaporation of the solvent. The degree of speed. The heat from the carrier layer 64 also cures the binder in the mixture, leaving a fixed phosphor layer on the carrier layer. The carrier layer 64 can be heated to a number of different temperatures. Solvent evaporation and adhesive curing speed. Suitable temperature range is 90 ° C to 150 ° C, but it should be understood that other temperatures can also be used. Various deposition methods and systems are described in Donofri〇 et al. "Systems and Methods For Application of Optical

US Patent Application Publication No. 2010/0155763 to Materials to Optical Elements, and the disclosure has also been assigned to creeInc. The phosphor layer 66 can have a number of different thicknesses depending, at least in part, on the concentration of the phosphor material and the desired amount of light to be converted by the phosphor layer 66. The phosphor layer according to the present invention can be coated with a concentration level (phosphor load) of more than 30%. Other embodiments may have a concentration level above 50%, while in still other embodiments, the concentration level may be higher than 6G% e. In some embodiments, the dish layer may have from 10 microns to 100 microns. The thickness within the range, while in other embodiments the 'scale layer' may have a thickness in the range of 4 Å to 5 Å (4). The methods described above can be used to coat the same layer of the same or different phosphor materials&apos; and different disc materials can be coated in different regions of the carrier layer using known techniques such as &apos;masking processes. Other embodiments may include uniform and/or non-uniform distribution of phosphors in the phosphor support, such as having different thicknesses of the layer of light and/or different concentrations of scale material along the support. 154499.doc •35· 201144699 There can be multiple regions of different types of light bodies that can emit light of the same or different colors, such as by distinct regions/layers with different phosphors. Some of these configurations may impart a patterned appearance to the phosphor carrier, some of which include, but are not limited to, strip, speckle, cross, zigzag, or any combination of such patterns. In still other embodiments, there may be a plurality of remotely separated phosphors (e.g., domes) that may have different types of phosphor materials. Each of these remote phosphors can have one or more phosphors that can be configured in many different ways as described above. The method described above provides some thickness control for the phosphor layer 66, but for greater thickness control, known methods can be used to grind the lining layer to reduce the thickness of the luminescent layer 66 or level each entire layer. The thickness above. This grinding feature provides the added advantage of being able to produce a lamp that emits within a single sorting level on the CIE chromaticity diagram. Sorting is generally known in the art and is intended to ensure that the LEDs or lamps provided in groups emit light in an acceptable range of colors. The LEDs or lamps can be tested and sorted into different sorting levels by color or brightness (generally referred to as sorting in the art). Each sorting level typically contains one color and The LEDs or lights of the brightness group' are typically identified by a sorting level code. White LEDs or lamps can be classified by chromaticity (color) and luminous flux (brightness). Controlling the thickness of the phosphor layer provides greater control in producing a lamp that emits light within the target sorting level by controlling the amount of source light converted by each phosphor layer. Each phosphor having the same thickness can be provided. A plurality of carriers of layer 66. By using light sources 58 having substantially the same luminescent properties, lamps having nearly identical emission characteristics of 154499.doc -36 - 201144699 can be fabricated, which in some examples can be within a single sorting level. In some embodiments, the illumination of the lamp is within a standard deviation from a point on the CIE map, and in some embodiments, the standard deviation comprises a Meadams ellipse that is less than a 10-step (step). In some embodiments, the illumination of the lamp belongs to a 4-step MacAdam ellipse centered at CIExy (〇 313, 0.323). The conversion element 62 can be mounted and bonded over the opening in the light source and/or cavity 54 using a different known method or material, such as a thermally conductive bonding material or thermal grease. Conventional thermal greases may contain ceramic materials such as yttria and aluminum nitride, or metal particles such as colloidal silver. In other embodiments, a phosphor carrier can be mounted over the opening using a thermally conductive device such as a clamp mechanism, screw or thermal adhesive to thereby tightly hold the conversion element 62 to the heat sink structure for heat The conductivity is maximized. In one embodiment, a thermal grease layer having a thickness of about 1 〇〇 μηη and a thermal conductivity of ^02 w/m_k is used. This has provided an effective thermal path for dissipating the thermal (four) optical layer 66. As mentioned above, different lamp embodiments without cavities can be provided, and the scale carrier can be mounted in many different ways, except above the opening of the cavity. During operation of the lamp 50, phosphor conversion heating is concentrated in the phosphor layer %, such as concentrated in the center of the phosphor layer 66, and most of the led light strikes the conversion element 62 at the center of the phosphor layer 66 and passes through the conversion element 62. The thermally conductive nature of the carrier layer 64 causes the heat to spread laterally toward the edge of the conversion element, as shown by the first heat flow 70. Heat is passed through the layer of thermal grease at the edges and into the fin structure 52, as shown by the second heat flow 72, in which the heat can be efficiently dissipated to the fins 154499.doc • 37· 201144699 Environment. As discussed above, the platform 56 and the (four) sheet structure 52 can be thermally coupled or coupled in the lamp 5G. This coupling configuration causes the conversion element (4) and the light source 58 to at least partially share a thermally conductive path for dissipating heat. The heat from the light (4) through the platform 56 (as shown by the third heat flow 74) can also be spread to the heat sink structure μ. The heat flowing from the conversion element 62 to the heat sink structure 52 can also flow into the platform 56. In other implementations, conversion element 62 and light source 58 may have separate thermally conductive paths for dissipating heat, wherein such separate paths are referred to as "handled." It should be understood that in addition to the embodiment shown in Figure 4, the conversion elements and/or the multiple (four) optical layers can be configured in many different ways. The or plurality of scale layers may be on either or both of the interior or exterior of the carrier layer or may be mixed into the carrier layer. The phosphor support may also comprise a scattering layer which may be included on the phosphor layer or carrier layer or mixed in the phosphor layer or carrier layer. It should also be understood that the phosphor and scattering layer may not cover the entire surface of the carrier layer&apos; and in some embodiments, the conversion layer and the scattering layer may have different concentrations in different regions. It should also be understood that the carrier may have surfaces of different roughness or shape to enhance transmission through the carrier. As discussed above, the diffuser 75 is configured to disperse light from the conversion element and/or source into a desired lamp emission pattern and can have many different shapes and sizes. In some embodiments, the diffuser can also be provided between the light source and the conversion element to disperse light primarily from the source only. In still other embodiments, the diffuser can be disposed over the conversion element to shield the conversion element when the light does not emit any light. The diffuser can have a material to impart a substantially white 154499.doc -38 - 201144699 appearance to impart a white appearance to the bulb when the lamp is not illuminated. A number of different diffusers having different shapes and attributes can be used with the lamp 50 and the lamps described below, such as those described in the following application: "LED Lamp With Remote" filed on March 3, 2010 U.S. Provisional Patent Application Serial No. 61/339,515, the entire disclosure of which is incorporated herein by reference. The diffuser can also be in a different shape 'including but not limited to a substantially asymmetrical "flat" shape, such as 2〇1〇1〇8 曰申清" entitled "Non-uniform Diffuser to Scatter Light Into Uniform In U.S. Patent Application Serial No. 12/901,405, the entire disclosure of which is incorporated herein by reference. • Lamps in accordance with the present invention may include many different features in addition to those described above. Referring again to Figure 4, in their lamp embodiment, the cavity 54 can be filled with a transparent thermally conductive material to further enhance the heat dissipation of the lamp. The two-cavity conductive material can provide a secondary for dissipating heat from the source 58. path. Heat from the source will still be conducted via the platform 56, but may also pass through the cavity material to the fin structure 52. This situation will allow for a lower operating temperature of the source 58, but a risk of an elevated operating temperature for the conversion element 62. This kind of p is not (4), but it is especially suitable for lamps with higher light source (with the fall of the phosphor layer, and the extra twist of the w-box conversion element). Allowing more efficient dispersion from the source as discussed above, different lamp embodiments in accordance with the present invention may be configured with a number of different types of light sources 154499.doc - 39 · 201144699. In one embodiment, eight may be used One or nine LEDs connected in series to the circuit board by two wires. The wires can then be connected to the power supply unit described above. In other embodiments, Eight or more or eight or fewer LEDs, and as mentioned above, LEDs available from Cree, Inc., including eight XLamp® XP-E LEDs or four XLamp® ΧΡ G LEDs. Different single-string LED circuits are described in the following U.S. Patent Application: U.S. Patent Application Serial No. i2/ entitled "Color Control of Single String Light Emitting Devices Having Single String Color Control" by van de Ven et al. 566, 195, and v An de Ven et al., U.S. Patent Application Serial No. 12/704,730, the entire disclosure of which is assigned to the same assignee. This is incorporated herein by reference. Figure 5 shows an alternative embodiment of a lamp 1 不 according to the present invention, the lamp 1 〇〇 may comprise an optical cavity similar to one of the optical chambers (not shown) and a Heat sink structure 102. Similar to the above embodiment, a lamp 1 without a lamp cavity may be provided, wherein the LED is mounted on the surface of the heat sink 102 or mounted on a three-dimensional structure or a base structure having a different shape. A planar, light-based source 104 is mounted to the platform 100' and a conversion element 108 is mounted over the light source 1-4, wherein the conversion element 108 has any of the features described above. In the illustrated embodiment, the conversion element 108 can Is substantially spherical in shape and may also comprise a thermally conductive transparent material and one or more distinct phosphor layers. Conversion element 154499.doc • 40· 201144699 piece 108 may be as described above A thermally conductive material or device is mounted to the heat sink or platform. The cavity (if provided) can have a reflective surface to enhance emission efficiency, as described above. Light from source 104 passes through conversion element ,8, in which the conversion element One portion of the light is converted by the one or more distinct phosphor layers in the conversion element 108 into one or more different wavelengths of light. In an embodiment, the light source 1〇4 may comprise a blue light emitting LED, and the conversion element ι 8 may comprise a distinct yellow phosphor layer and/or a distinct red phosphor layer as described above, the phosphor layers Absorbs a portion of the blue light and re-emits yellow and/or red light. The lamp 1 〇〇 emits LED light combined with the white light of the constituting layer light. Similar to the above, the light source 〇4 may also comprise a plurality of different LEDs emitting light of different colors, and the conversion element i 〇8 may comprise other dissimilar phosphor layers (each comprising a phosphor type or a mixture of phosphor types) to produce The color temperature and color rendering light. It should be understood that the phosphor layer may be located on the outer surface of the carrier layer of the conversion element 〇8, may be located on the interior of the carrier layer, and/or one or more phosphor layers may be located on the interior of the carrier layer, and one or more Other phosphor layers may be located on the exterior of the carrier layer. It should also be understood that the different phosphor layers can be placed in a certain order such that the phosphor layer of the lower wavelength converter is closest to the source, while the phosphor layer of the highest wavelength converter is farther from the source, and any intervening phosphor layers are the same. Mantle - order. Conversely, the distinct scale layers can be ordered such that the highest wavelength converter phosphor layer is closest to the source, while the lowest wavelength converter phosphor layer is farther from the source and any intervening phosphor layers are similarly ordered. The conversion element 108 can also include a bandpass filter (such as a dielectric mirror or an anti-reflective coating), and the passable filter can be included inside or outside the conversion element sphere/dome 154499.doc • 41 - 201144699 and/or Or on the inside or the outside of the diffuser element sphere/dome" substantially, the side of the bandpass acts as a light reflector and the other side acts as a light transmissor. This is done by reflecting light of a wavelength greater than a specific value (such as &gt; 5〇〇ηΐη) and transmitting light of a wavelength less than a specific value (such as &lt; 5 〇〇 nm). In an illustrative implementation, the (four) pass filter can reflect longer wavelengths (such as yellow light or any light greater than 5 〇〇 nm2) while transmitting shorter wavelengths (such as blue light or less than 5 〇〇〇〇 1) Any light). Ideally, the bandpass filter can be provided to ensure that light from the wavelength emitted by the LED does not return to the source, but instead is transmitted out of and away from the source for passage through the switching element and the diffuser element. In a possible embodiment, the bandpass filter can be located in one or more of the distinct phosphor layers on the conversion element. The bandpass filter can be designed to transmit blue (the color emitted from the blue LED) and reflect longer wavelengths. However, it should be understood that the bandpass filter can be designed to transmit any other desired color. In this possible embodiment, light from the wafer will pass through the filter and move to the phosphor layer and diffuser elements. At least some of the light converted in the phosphor layer can be emitted back to the bandpass filter, which will then reflect the converted higher wavelength light away from the source and reflect to the user . The band pass filter can comprise a number of suitable materials known in the art. For example, materials commonly used for dielectric mirrors and anti-reflective coatings can be used. Such materials include, but are not limited to, MgF, Ti02, SiO2, Zr02, Al〇2, and Ta205. The lamp 100 also includes a shaped diffuser sphere mounted on the light source 1〇4/154499.doc-42·201144699 dome 110, the shaped diffuser sphere/dome 110 including such diffusions as listed above or Diffusion or Scattering Particles of Scattering Particles Although the diffuser is shown externally to the conversion element in this embodiment, it should be understood that the diffuser element can also be internal to the conversion element and/or incorporated within the conversion element. The scattering particles can be provided in a curable binder formed into a general shape of a sphere/dome. In the illustrated embodiment, the dome 11 is mounted to the heat sink structure 102. Different binder materials such as polyoxygen, epoxy, glass, inorganic glass, dielectric, BCB, polyamine, plastic, polymers, and mixtures thereof, as discussed above, can be used. In some embodiments, white scattering particles can be used within a white sphere/dome that hides the color of the phosphor layer in the conversion element 108, which gives the entire lamp a white appearance and a phosphor layer The color is generally more visually acceptable to consumers or more attractive to consumers than the white appearance. In one embodiment, the diffuser can comprise white titanium dioxide particles, and the white titanium dioxide particles can impart an overall white appearance to the diffuser sphere/dome 11. The diffuser sphere/dome 1H) provides the added benefit of distributing the light emitted from the source in a more uniform pattern. As discussed above, light from the source can be emitted in a substantially Lambertian pattern&apos; and the shape of the sphere/dome and the scattering properties of the scattering particles cause the light to be emitted from the dome in a more omnidirectional emission pattern. The engineered sphere/round material has different concentrations of scattering particles in the (four) towel or can be shaped into a specific emission pattern. In the United States, the ENERGY STAR 8 program, which was implemented by the US Environmental Protection Agency and the United States (4), published a standard for integrated coffee lamps, and the measurement techniques for both color and angle uniformity are described in ENERGY STAR 8 Program 154499.doc -43· 201144699 is incorporated herein by reference. For a vertically oriented lamp, the luminous intensity is measured in a vertical plane relative to the initial plane 4 5 and 90. The δ ray intensity will differ from the lamp's overall 〇° to 135. The average intensity of the zone differs by no more than 20% 'where zero is defined as the top of the bulb shell. In addition, 5% of the total flux from the lamp will be at 135. In some of the embodiments (including the embodiments described below), the diffuser sphere/dome can be engineered such that the emission pattern from the lamp is incorporated by reference. The ENERGY STAR 8 Program Requirements for Integrated LED Lights as amended on March 22, 2010 (ENERGY Lights 8)

Program ReqUirements for Integral LED Lam (four) △ Quan Ding emission guidelines. One requirement in this standard that is met by the lamps herein is that the uniformity of transmission must be within 2% of the average of the measurements from 0 〇 to 135 。. Another requirement is that more than 5% of the total flux from the lamp must be at 135. The emission is carried out in the 180° emission area, where the measurement system is in the 〇. 45. And 9〇. Performed under azimuth. As mentioned above, the different lamp embodiments described herein may also

Includes A-type (eg, A19) trim LED bulbs that meet DOE ENERGY STAR® standards. The present invention provides an efficient, reliable, and cost effective lamp. In some embodiments, the entire lamp can include five components that can be assembled quickly and easily. Similar to the above embodiment, the lamp 100 can include a mounting mechanism 112 of the type to be installed in a conventional electrical socket, the mounting mechanism 112 being connected To the heat sink 1〇2. In the illustrated embodiment, the lamp 1 〇〇 includes a threaded portion 112 for mounting to a standard threaded yoke. - Like the above embodiment, the lamp 1 〇〇 can include a standard plug and the electrical socket can be a standard socket 'or Includes GU24 base unit, or 154499.doc • 44· 201144699 Lights _ can be clips and electrical sockets can be sockets that receive and hold the clips (eg 'as used in many camp lights). The heat sink structure may also include an internal cavity or housing that holds the power supply or power conversion empires components as described above. As mentioned above, the space between the features of the lamp 100 can be considered as a mixing chamber&apos; wherein the space between the source 104 and the conversion element 108 comprises a first-light mixing chamber. The space between the replacement element 108 and the diffuser 110 can include a second light mixing chamber that promotes uniform color and intensity emission of the lamp. The same can be applied to embodiments having different shapes of the conversion element and the diffuser. In other embodiments, additional diffusers and/or conversion elements forming additional mixing chambers may be included, and the diffusers and/or conversion elements may be configured in a different order. Figures 6 to 8 depict various possible configurations of the conversion element 1〇8 in accordance with the present invention, which may be incorporated into possible lamp device commands. It should be understood that the various possible conversion elements 108 are shown for illustrative purposes only and are not meant to narrow the scope of the invention and its various possible embodiments. Three or more distinct phosphor layers can be provided in any embodiment as desired and the phosphor layers can be positioned in any order relative to the carrier layer as desired. In FIG. 6, a phosphor carrier layer carrier layer 114 similar to the phosphor carrier layer described in detail above is provided as a sphere/dome, but the shape may depend on the overall emission of the lamp, light mixing, and light. Changes in conversion characteristics. The carrier layer 114 can be coated with a distinct phosphor layer 116, wherein the phosphor layer comprises a red, yellow or green phosphor. Layer 116 may also comprise phosphors of two or more types. The inner surface and/or the outer surface of the carrier layer 114 may be coated with 154499.doc • 45· 201144699 cloth phosphor layer 116 » In Fig. 7, the moth carrier layer 114 is again provided, but in this embodiment 'the opposite layer 114 coating two distinct phosphor layers 116, 118. The bowl of light layers 116, 118 may coat the inner, outer or inner and outer surfaces of the carrier layer 4, and may each comprise a distinct red, yellow or green layer. If the layers are coated inside and outside the carrier layer, a dissimilar layer of light may coat the inner surface of the carrier layer, and another dissimilar layer may coat the outer surface of the carrier layer. One or both of the phosphor layers 116, 118 may also comprise a mixture of two or more types of phosphors in each layer. As a non-limiting example, in a possible embodiment of a lamp with a blue LED, it may be desirable to include a distinct red and yellow light blocking layer 'where the red layer is closest to the light source. The red phosphor layer will absorb some of the blue light and convert it to red light&apos; and the yellow phosphor layer will absorb some of the blue light and convert it to yellow light without substantially absorbing some of the red light. The resulting light emission will produce a combination of red, yellow and blue light that can be emitted from the lamp structure as white light. This configuration also helps to avoid double down conversion of various wavelengths. However, in some embodiments, double down conversion may be desirable, in which case different phosphor layer orders and/or different phosphor layer compositions may alternatively be used. In Figure 8, the phosphor is again provided. The carrier layer 114, but in this embodiment, the layer 114 may be coated with three distinct phosphor layers 116, 117, ι 8 〇 phosphor layers 116, 117, 118 to coat the inner surface, outer surface of the carrier layer 114 or Both inner and outer surfaces, and each may comprise a distinct red, yellow or green layer, and/or one, two or all three phosphor layers may also be included in each 154499.doc • 46 · 201144699 layer A mixture of two or more phosphor types. In addition, it is to be understood that one or more of the distinct phosphor layers may coat the inner surface of the carrier layer and one or more other distinct phosphor layers coat the outer surface of the carrier layer. As a non-limiting example, in a possible embodiment of a lamp structure with a blue LED, it may be desirable to include distinct red, yellow, and green phosphor layers with a reddish layer closest to the source and a green layer from the source. Farther. The red, yellow, and green layers will absorb some of the blue light from the LEDs and re-emit light at the H and green wavelengths of the respective colors, where the yellow layer does not substantially absorb red light and the green layer does not substantially absorb yellow. Light. The resulting light emission will produce a combination of red, yellow, green, and blue light that can be emitted from the lamp structure as white light. This configuration also helps to avoid double down conversion for various wavelengths. However, in some embodiments, double down conversion may be desirable, in which case different phosphor layer orders and/or different phosphor layer compositions may alternatively be used. As discussed above, different lamp embodiments in accordance with the present invention can have many different shapes, sizes, and configurations. Figure 9 shows another embodiment of a lamp cartridge 2 in accordance with the present invention. Lamp 120 is similar to lamp 1 and similarly includes a heat sink structure 102 in which light source 1 is mounted to platform 1. Like the above, the heat sink structure 102 can also include an optical cavity. As above, the light source can be provided on other structures than the heat sink structure. Such structures may include a planar surface or pedestal having a light source. The diffuser ball/dome element 122 is mounted over the light source 104. The diffuser element 122 can be made of the same material as the diffuser described above. Lamp 120 can also include conversion element 124, but in this embodiment, conversion element 124 is placed external to diffuser 122. As described above, the conversion element 154499.doc -47 - 201144699 124 may comprise a carrier layer and - or a plurality of phosphor layers. In some applications, it may be desirable to place the diffuser element 122 inside the conversion element 124, in which the increased emission of light and the light from the source are before the light reaches the phosphor layer on the conversion element. The mixing can be desired (for example, in the case of using multiple color LEDs in a light source). However, this type of diffusion can also be equated with less light conversion because the light emitted from the source will have no chance to pass through the phosphor layer before reaching the diffuser 122. In addition, more phosphors may be required in this configuration due to the larger surface area of the conversion element. Figure 10 shows another embodiment of a lamp 130 in accordance with the present invention, the lamp 130 being similar to the lamp 100 and similarly comprising a heat sink structure 1〇2, the ten light sources 1〇4 being mounted to the platform 106 〇 similar to the above, the heat sink structure 1〇2 can also include an optical cavity. As above, the light source can be provided on other structures than the heat sink structure. The lamp m can also comprise a conversion element 132 which, as described above, has a carrier and/or a plurality of distinct phosphor layers, but in this embodiment the 'transformation element 132 is elongate and tubular to provide Different wavelength conversion characteristics. S 130 can also include a diffuser member 134 disposed external to conversion element 132, but in this embodiment, diffuser 134 is flattened or flat to provide a different lamp emission pattern. The diffuser 134 can mask the color of the phosphor layer from the conversion element 132. It should be understood that in other lamp implementations, the conversion element and diffuser can take many different shapes&apos; including different three-dimensional shapes or planar configurations. As discussed above, 'when each phosphor layer absorbs and re-emits light, it re-emits light in an isotropic manner, causing the shape of the conversion element to convert light from the source of 154499.doc •48- 201144699 and also Light from the source is dispersed. Similar to the diffusers described above, the different shapes can be illuminated in accordance with emission patterns having different characteristics, depending in part on the emission pattern of the source. The diffuser can then be matched to the emission of the conversion element to provide the desired lamp emission pattern. It will be understood that the phosphor layer may be on the inner or outer layer of the carrier, mixed in the carrier, or any combination of the above three. In some embodiments, having a phosphor layer on the outer surface minimizes emission losses. When the illuminator light is absorbed by the phosphor layer, the light system emits omnidirectionally, and some of the light can be emitted backwards and absorbed by a lamp element such as an LED. The phosphor layers may each also have a different index of refraction than the carrier layer such that light emitted forward from each phosphor layer may be reflected back from the inner surface of the carrier. This light can also be lost due to absorption by the lamp element. In the case where each or at least some of the phosphor layers are on the outer surface of the carrier, the light emitted forward does not need to pass through the carrier and will not be lost due to reflection. Light that is emitted backwards may hit the top of the carrier where at least some of the light is reflected back. This configuration can result in a reduction in light emitted from each phosphor layer back into the carrier (in the carrier, light can be absorbed). Each of the phosphor layers can be deposited using many of the same methods described above. In some instances, the three-dimensional shape of the carrier may require additional steps or other processes to provide the necessary coverage. In embodiments in which the solvent-phosphor-binder mixture is sprayed, the carrier can be heated as described above, and multiple nozzles may be required to provide the desired coverage (e.g., near uniform coverage) over the carrier. In other embodiments, fewer nozzles can be used while rotating the carrier to provide the desired coverage. Similar to the above, the heat from the carrier evaporates the solvent and helps to cure the binder. 154499.doc • 49· 201144699 In still other embodiments 'each phosphor layer can be formed via an emersi process> whereby each phosphor layer can be formed on the inner or outer surface of the carrier, but It is particularly suitable for being formed on the inner surface. The support may be at least partially filled with a phosphor or phosphor mixture adhered to the surface of the support, or otherwise contact the support with a phosphor or phosphor mixture. The individual phosphor or phosphor mixture may then be discharged from the support, thereby on the surface The phosphor or mixture layer is left and the phosphor or mixture layer can then be cured. In one embodiment, the mixture may comprise polyethylene oxide (PEO) and a phosphor. The carrier can be filled and then the carrier can be evacuated to leave the PEO·phosphor mixture layer&apos; which can then be thermally cured of the pE〇-phosphor mixture layer. PE0 evaporates or is dissipated by heat, leaving a phosphor layer. In some embodiments, an adhesive may be applied to further secure the phosphor layer, while in other embodiments, the phosphor may remain without a binder. Similar to the process for coating a planar carrier layer, such processes can be used in a three-dimensional carrier to coat multiple, distinct phosphor layers that can have the same or different phosphor materials. The phosphor layer may also be applied to both the interior and exterior of the carrier, and may have different types having different thicknesses in different regions of the carrier. In still other embodiments, different processes may be used, such as coating the carrier. A sheet of phosphor material is applied which is thermally formed to the carrier. In the lamp using the carrier according to the present invention, the illuminator can be disposed at the base of the carrier such that light from the illuminator is emitted upward and through the carrier. In some embodiments, the illuminator can illuminate in a substantially Lambertian pattern, and the carrier can help disperse the light in a more uniform pattern. As noted above, the conversion element can comprise a plurality of conversion materials, such as yellow 154499.doc -50· 201144699 color, green, and red phosphors. These phosphors provide a component of light for the white light to emit. However, in different embodiments, such light components may be provided directly from the LED wafer rather than being provided via phosphor conversion. These different configurations may provide certain advantages including, but not limited to, lamps that require lower operating power and that are less expensive by eliminating the need for a particular phosphor. In other embodiments, some of these color components may be provided directly from LED chips of different colors. For example, the red component of the emission can be provided directly from the red illuminating LED described in the following application: U.S. Provisional Patent Application No. 61, entitled "LED Lamp With Remote Phosphor and Diffuser Configuration Utilizing Red Emitters" by Yuan et al. / 424, 670, the disclosure of which is incorporated herein by reference. Different lamp assemblies can have many different shapes and can be configured in many different ways. In particular, the heat sink can be configured in a number of different ways to meet the desired size, thermal management characteristics, and desired emission characteristics of the lamp. In addition, the shape of the conversion element and the diffuser element can affect the various emission characteristics of the lamp. Various possible heat sink/thermal management configurations and conversion elements and diffuser shapes and orientations are described in U.S. Patent No. 61/43,759, which is incorporated herein by reference. The application of the 61/435,759 application also teaches: the various methods and mechanisms of the present invention, various security features, and various diffuser dome concentration regions in accordance with the present invention are also incorporated herein by reference. As discussed above and in the patent application (4) herein, the diffuser dome in accordance with the present invention can have different zones that scatter and transmit different amounts of light from the light source to help produce the desired lamp emission (4). In some embodiments, the different regions of the scattering and transmission of different amounts of light can be achieved by coating the diffuser dome with different amounts of diffusion material at different zones. This situation, in turn, modifies the output beam intensity profile of the source to provide improved emission characteristics, as described above. In some embodiments, the present invention may rely on a combination of diffuser elements (i.e., diffuser domes) and diffuser coating scattering properties to produce a desired far field strength profile of the lamp. In various embodiments, the diffuser thickness and position may depend on various factors, such as the diffuser dome geometry, the source configuration, and the pattern of light emitted by the barrier carrier. It should also be understood that the conversion element can have regions of varying concentrations of conversion material (i.e., phosphors). This situation can also assist in generating the desired emission profile as well as the desired light characteristics. In some embodiments, the conversion element can have an increased conversion material at or around the top, but the increase can be in other areas. It will also be appreciated that similar to the diffuser coating, the conversion material can be applied to the carrier layer or to the carrier layer by any of the various internal and external coating combinations described above. It will be understood that a lamp or bulb in accordance with the present invention may be configured in a number of (four) ways other than the embodiments described above. The ± (iv) embodiment is discussed with reference to the far-end phosphor, but it should be understood that alternative embodiments may include at least some of the LEDe having a conformal fill layer. This situation may be particularly useful for emitting different colors from different types of illuminators. Light source of light. These embodiments may additionally have some or all of the features described above. Although the invention has been described in detail with reference to certain preferred embodiments of the invention, other forms are possible. For example, various features or aspects of the LED light bulb of the present invention are described with respect to various embodiments, but it should be understood that any of the embodiments described herein may be described. Each of these features or aspects is used in a similar manner and will be understood by those skilled in the art. Therefore, the spirit and scope of the present invention should not be limited to the types described above. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows a cross-sectional view of one embodiment of a prior art LED package; Figure 2 shows a cross-sectional view of another embodiment of a prior art LED package; Figure 3 shows the size specification of the A19 replacement bulb; Figure &gt; BRIEF DESCRIPTION OF THE DRAWINGS FIG. 5 is a cross-sectional view of one embodiment of a lamp in accordance with the present invention; FIGS. 6-8 are cross-sections of different embodiments of a conversion element in accordance with the present invention. Figure 9 is a cross-sectional view of one embodiment of a lamp in accordance with the present invention; and Figure 10 is a cross-sectional view of one embodiment of a lamp in accordance with the present invention. [Main component symbol description] 10 Typical LED package 11 wire bond 12 led chip 13 Reflector cup 14 Clear protective resin 15A Wire 16 Encapsulant material 20 Conventional LED package I54499.doc 201144699 22 LED chip 23 Substrate or sub-substrate 24 Metal reflection 25 Α Electrical trace 25 Β Electrical trace 26 Encapsulant 27 Wire bond 30 A19 size bulb 50 Light 52 Heat sink structure 53 Reflective layer 54 Optical cavity 56 Platform 58 Light source 60 Heat sink fins Wavelength conversion element 72 Second Heat flow 74 Third heat flow 76 Diffuser element 100 Lamp 102 Heat sink structure 104 Light source 106 Platform 108 Conversion element 154499.doc · 54· 201144699 110 Diffuser sphere / dome 112 Mounting mechanism 114 Phosphor carrier layer 116 Phosphor layer 118 Phosphor layer 120 lamp 122 diffuser sphere / dome element 124 conversion element 130 lamp 132 conversion element 134 diffuser element 154499.doc -55·

Claims (1)

201144699 VII. Patent application scope: 1 . An illumination device comprising: a solid state light source; a diffuser element spaced apart from the light source; and a wavelength conversion element spaced apart from the light source and the diffuser element Wherein the wavelength converting element comprises one or more distinct scale layers for converting light emitted from the source. 2. The illumination device of claim 1 which emits an emission pattern as required by ENERGY STAR®. 3. The illumination device of claim 1, wherein the light source comprises one or more light emitting diodes (LEDs). 4. The illumination device of claim 3, wherein the light emitting diodes comprise blue LEDs. 5. 5. The illumination device of claim 3, wherein the light emitting diodes comprise blue and red LEDs or any combination of LEDs . 6. The illumination device of claim 1, wherein each of the cans of light comprises a single color phosphor or a single or multiple phosphor types. 7. The illumination device of claim 1, wherein the phosphor layers are ordered such that the lowest wavelength converter phosphor layer is closest to the source&apos; and the highest wavelength converter phosphor layer is further from the source. 8. The illumination device of claim 1, wherein the fill layers are ordered such that the highest wavelength converter phosphor layer is closest to the source&apos; and the lowest wavelength converter phosphor layer is further from the source. 9. The illumination device of claim 1, wherein the layer 154499.doc 201144699 layer closest to the light source comprises a red phosphor, and the edge layer farthest from the light source comprises a green phosphor and The phosphor layer between the red layer and the green layer comprises a yellow scale. 10. The illumination device of claim 1, wherein the device is configured to be mounted within the A19 bulb housing while simultaneously emitting a substantially uniform emission pattern. 11. The illumination device of claim 1, wherein the phosphor layers comprise distinct red, yellow, and green phosphor layers or any combination thereof. 12. The illumination device of claim 1, wherein the diffuser element comprises a sphere at least partially coated with a diffusion material. 13. The illumination device of claim 1, wherein the diffuser element disperses light from the source, light from the wavelength conversion element, or light from a combination of the source and the wavelength conversion element. 14. The illumination device of claim 1, wherein the wavelength converting material and the diffuser element comprise a double sphere structure. 15. The illumination device of claim 1, further comprising a thermal management structure. 16. The illumination device of claim 1, wherein the different phosphor layers, the composition of each phosphor layer, and/or the order of the phosphor layers are reduced in conversion from the source compared to other remote phosphor applications The amount of phosphor required for the light is as follows: The diffuser improves the color uniformity and brightness and contributes to a wider viewing angle. 18. A lighting device as claimed in the 'where the diffuser can be disposed outside the rotating element, inside the converting element, or incorporated in the converting element. 19. As requested by the lighting device, the step further comprises The conversion element 154499.doc -2 - 201144699 or a bandpass filter on the diffuser acts as a reflector for a particular wavelength range and a transponder for a different particular wavelength range. 20. The illumination device of claim 1, wherein the wavelength conversion element is coated on one side with a polyoxynitride layer and on the other side with one or more of the phosphor layers. 21. The illumination device of claim 1, wherein the conversion element comprises a substantially transparent layer of carrier material. 22. The illumination device of claim i, wherein the diffuser at least partially conceals the appearance of the wavelength converting material when the illumination device is not illuminated. 23. The illumination device of claim 1, wherein the light source is mounted on a printed circuit board mounted to a heat sink, the printed circuit board further comprising a protective layer to cover conductive features on the PCB. 24. The illumination device of claim 1, wherein the light emitted from the diffuser has a spatial uniformity that is self-contained. To 135. One of the inspection angles is within 20% of one of the average values. 25. If the lighting device is requested, it is at 135. To 18 baht. The inspection angle has more than 5% of the total luminous flux. 26. A lighting device comprising: a solid state light source; a diffuser element over the light source; and a wavelength converting element above the light source, wherein the wavelength converting element comprises One or more distinct scale layers of light emitted by the source. 154499.doc 201144699 27. A solid state light comprising: a solid state light source; a diffuser element 'being above and spaced apart from the light source; and a wavelength converting element 'in the light source and the diffuser Above and spaced apart from the light source and the diffuser element, wherein the wavelength converting element comprises one or more dissimilar phosphor layers for converting light emitted from the light source; wherein the diffuser element and the wavelength converting element Provide a double sphere structure. 28. A solid state light comprising: a solid state light source; a diffuser element above and spaced apart from the light source; and a wavelength conversion τ member over and spaced apart from the light source Wherein the wavelength converting element comprises one or more distinct light layers for converting light emitted from the light source; wherein the diffuser element is above and spaced apart from the wavelength converting element Element and the wavelength conversion element provide a double sphere structure" 154499.doc