TW201405073A - Solid-state linear lighting arrangements including light emitting phosphor - Google Patents

Abstract

A solid-state linear lamp comprises a co-extruded component, the co-extruded component comprising an elongate lens and a layer of photoluminescent material. The elongate lens is for shaping light emitted from the lamp and comprises an elongate interior cavity. The layer of a photoluminescent material is located on an interior wall of the elongate interior cavity. The lamp further comprises an array of solid-state light emitters configured to emit light into the elongate interior cavity.

Description

Solid state linear lighting configuration with luminescent phosphor

The present invention relates to solid state linear illumination applications that include a luminescent phosphor (photoluminescent material) to produce light of a desired color, i.e., light that is within a portion of a wavelength spectrum of a solid state illuminator. In particular (but not exclusively), the present invention relates to LED-based illumination configurations that produce light in the visible portion of the spectrum and, in particular, but not exclusively, produce white light. Moreover, the present invention provides an optical assembly for use in such a lighting arrangement and a method of making an illumination arrangement and an optical assembly.

White light emitting diodes (LEDs) are known in the art and are relatively recent innovations. Until the development of LEDs that illuminate in the blue/ultraviolet region of the electromagnetic spectrum, the development of LED-based white light sources has become practical. As is conventionally known, an LED that produces white light ("white LED") comprises a phosphor that is a photoluminescent material that absorbs a portion of the radiation emitted by the LED and re-emits a different color (wavelength). radiation. For example, the LED emits blue light in the visible portion of the spectrum and the phosphor re-emits yellow light. Alternatively, the phosphor can emit green light and red light, green light and yellow light, or a combination of yellow light and red light. The portion of visible blue light emitted by the LED that is not absorbed by the phosphor mixes with the emitted yellow light to provide light that appears to the naked eye to be white. It is expected that white LEDs may replace incandescent light sources due to their long life span of hundreds of thousands of hours and their high efficiency. High-brightness LEDs have been used in vehicle brake lights and indicators to And traffic lights and flashlights.

To increase the intensity of light emitted from an LED, it is known to include a lens made of a plastic material or glass to focus the light emission and thereby increase the intensity. Referring to Figure 1 , a high brightness white LED 2 is shown . The LED 2 comprises an LED wafer 4 mounted in a plastic or metal reflector cup 6 and then encapsulated in an encapsulating material, typically an epoxy resin 8 . The encapsulating material comprises a phosphor material for providing color conversion. Typically, the inner surface of the cup 6 is silver plated to reflect stray light toward one of the lenses 10 mounted on the surface of the encapsulated epoxy 8 .

It should be appreciated that this configuration has limitations and the present invention is directed to at least partially alleviating such limitations. For example, for a high intensity LED having a high intensity output greater than 1 W, the high temperature at the output of the LED intimately associated with the phosphor material can induce a temperature dependence of the temperature of the system, and in some cases Thermal degradation of the phosphor material can occur. Furthermore, it is difficult to maintain the color uniformity of the light emitted by such LEDs in the case where the phosphors are distributed in the epoxy resin, since light of different path lengths will encounter and be absorbed by different amounts of phosphor. In addition, the fabrication of such LEDs is time consuming due to the encapsulation and subsequent placement of the lenses.

In accordance with an embodiment of the present invention, a linear illumination arrangement comprising a linear transparent optical lens for mixing and distributing light emitted from an LED and a phosphor is provided. The phosphor layer has a curved shape within an interior cavity of one of the linear optical lenses. The LEDs on a linear PCB are positioned away from the phosphor layer. In some embodiments, the lens is preferably fabricated from a rough surface to achieve efficient extraction of light. This linear illumination configuration may be referred to herein by way of example as a "linear lamp."

In some embodiments, a linear lamp includes an array of LED wafers mounted on a support member (eg, a printed circuit board mounted on the inside of the lens on the inside of the indentation/slot), wherein an inner cavity/chamber is formed in In the interior of the lens. The wall of the chamber contains a phosphor layer. The circuit The surface of the board may be formed or covered with a reflective material to direct light from the LED wafer away from the board and toward the phosphor. The light emitted by the LED wafer is converted by the phosphor into photoluminescent light, and the color quality of the final light emission output of the lamp is based, at least in part, on the wavelength of the photoluminescent light emitted by the phosphor and through the phosphor. A combination of wavelengths of any remaining light from the LED wafer. The color of the light emitted from the illumination arrangement can be controlled by appropriate selection of the thickness and/or loading of the phosphor composition and the phosphor within the phosphor layer, the thickness and/or load of the phosphor being determined from the phosphor. The ratio of the output light. To ensure a uniform output color, the phosphor layer is preferably of uniform thickness and has a typical thickness in the range of from 20 μm to 500 μm.

The configuration and shape of the lens can be configured to affect the actual pattern of light emitted from the lamp. In some embodiments, the lens has a semi-circular profile that, for example, covers a range of radial angles substantially corresponding to a central axis of the lens and the lamp permitting self-lighting in a desired direction The focus and distribution of the emitted light from the output. The lens can be made of any suitable material, such as a plastic material (such as polycarbonate, acrylic, polyfluorene) or glass (such as cerium oxide based glass) or any material.

The configuration and shape of the phosphor can be configured to affect the distribution of light emitted from the lamp. Some embodiments provide a phosphor that enhances one of the cone-shaped profiles of the amount of light distributed from the sides of the lamp. An alternative design is directed to a lamp in which the phosphor has a profile that is not as concentric as a semi-circular in nature, the lamp providing a relatively large distribution of light toward the center of the distribution region. The exact shape of the phosphor and/or lens can be selected and combined to provide any suitable output pattern and distribution as desired. Another benefit is that the lens is also used to provide a chamber in which light is mixed with minimal loss in a highly transparent solid body. An example of this occurs when a lamp contains both red and blue LEDs in the chamber, and the chamber allows light from such LEDs (eg, red light) to be evenly distributed inside the lens.

In some embodiments, the chamber in the lens is provided in a cavity within the lamp having a volume that is large enough for insertion of the LED array into the cavity. This permission LED Completely or partially within the interior of the lens and/or phosphor. The implementation of a cavity/chamber within the lens contributes to a very simple assembly and improved efficiency due to avoiding losses from an external mixing chamber.

Certain embodiments implement an optical material having a lens of clear or transparent nature, which provides the benefit of forming a linear optic/linear lens. Alternatively, the lens can be configured to operate to provide a collimated light pipe at the source such that light travels an extended distance inside the tube without leaving the side. The optical assembly can be configured with suitably curved sides to provide collimation functionality. In an alternate embodiment, the lens is not configured to extend along the entire length of the reflector. Rather, the lens typically forms a curved or dome-like shape that only partially fills the interior volume formed by the reflector. A coextrusion process can be used to fabricate the phosphor layer, lens and reflector structure. The concept of coextruding a phosphor and a lens into a single component is itself considered inventive.

In some embodiments, further operational efficiency of the lamp is provided by including an optical medium (eg, a solid optical medium) within the chamber. The optical medium within the chamber includes a material having a refractive index that is one that closely matches the phosphor, one of the refractive indices of the LED, and/or any type of encapsulating material that may be present on top of the LED. The optical medium can be selected from materials generally identifiable in materials commonly used in phosphors, LEDs, or materials that match the refractive index of such materials (eg, polyoxyn), and/or any encapsulating material used to surround the LED. In some embodiments, the lamp structure includes a plurality of "sandwich" structures in which a particular shape of phosphor layer is embedded between a front lens and a solid fill on the interior side. This structure can be fabricated by, for example, coextrusion of all three layers.

Some embodiments of a linear lamp include an elongate lens having a chamber integrally formed with one of the same length as the lens, wherein the chamber is shaped to provide a desired pattern of light distribution. A linear LED array is located on a circuit board and provides a reflective material comprising one of the apertures for the LED. Mount the board to a heat sink. The assembly including the heat sink, the circuit board, and the reflective material is to be disposed at the concave end portion of the lens A pair of end plates are attached to the lens. In embodiments in which the linear lamp is intended to be a direct replacement for a standard fluorescent lamp, an end cap is provided that includes a suitable connector (such as a G5 or G13 double pin connector) for assembly into a standard fluorescent lamp fixture. An external reflector can also be used in conjunction with the lamp to direct the output light into the desired direction.

The coverage angle of the lens is configurable to adjust the illumination pattern of the lamp. Increasing the coverage angle to 360 degrees will result in a full 360 degree illumination of a fixture. The bottom portion of the lens is configured such that the lens provides a semi-circular profile having an illumination angle (e.g., at a radial angle greater than or less than 180 degrees relative to a central axis of the lamp). The angle of the bottom portion of the lens can also be adjusted to adjust the illumination pattern of the lamp, the lamp being tilted in an outward or inward direction.

In some embodiments, a light diffusing layer can be provided to improve the visual appearance of the illumination device in an off state for an observer. The light diffusing layer comprises particles of a light-diffusing material, and the particles of a light-diffusing material substantially reduce external excitation that would otherwise cause the wavelength converting component to re-emit light of a wavelength having a yellowish/orange color The passage of light. For example, one of the light-diffusing layers of the light-diffusing layer is selected to have a size range that increases the probability of its scattered blue light, which means that less external blue light passes through the light-diffusing layer to excite the wavelength. Conversion layer. The light diffraction particle size can be selected such that the particles will scatter blue light (eg, at least two times) than the light produced by the phosphor material that it will scatter. Preferably, to enhance the white appearance of the illumination device in an off state, the light diffraction material in the light diffusion layer has one of the average particle sizes of "nano particles" of less than about 150 nm. For light sources that emit light of other colors, the nanoparticles may correspond to other average sizes. For example, for a UV light source, the light diffraction material within the light diffusing layer can have an average particle size of less than about 100 nm. Embodiments of the present invention can be used to reduce the amount of phosphor material required to fabricate an LED lighting product, thereby accounting for the relatively expensive nature of the phosphor material and reducing the cost of manufacturing such products. Specifically, the addition of a light diffusion layer composed of particles of a light diffraction material The addition substantially reduces the amount of phosphor material required to produce a selected color of emitted light. Different methods can be used to introduce the light scattering material into an LED lamp that substantially reduces the amount of phosphor material needed to produce the emitted light of a selected color. Additionally, the light diffusing layer can be used in conjunction with additional scattering (or reflecting/diffusing) particles in the wavelength conversion component to further reduce the amount of phosphor material required to produce the emitted light of a selected color. One possible method is where the light scattering material is contained within a separate layer. Another possible method is where the light scattering material is contained within a layer containing the phosphor. Yet another possible method is where a light scattering material is introduced into the lens. Any combination of the above methods can also be implemented. For example, the light scattering material can be introduced into both the phosphor layer and the lens. Additionally, the light scattering material can be included in both a separate layer and the phosphor layer. Additionally, the light scattering material can be included in each of the individual layers, the phosphor layer, and the lens.

An alternative approach can be taken to improve the white appearance of the off state of the lamp. For example, the texture can be incorporated into the exterior surface of the lamp, for example, in the outer surface of the lens to improve the off-state white appearance of the lamp. Yet another possibility is to implement a white thin layer just after the yellow phosphor layer and before clearing the linear optics. This three-layer structure will have a white appearance in the off state, but the primary optics will still be clear (non-diffusing/blurred). This method has the benefit of maintaining the light distribution pattern of the linear lens optics while still providing a white appearance.

The method of using an internal cavity as a "mixing chamber" can also be applied to a non-linear lamp. In some embodiments, an LED illumination configuration is provided wherein the lens includes a solid hemispherical shape and the LED wafer is mounted within the illumination configuration chamber such that it is completely contained within the interior of the phosphor profile. However, the lens can be fabricated to provide any suitable shape as desired. For example, one of the embodiments of the present invention replaces an LED illumination configuration in which the lens includes a solid oval shape.

With regard to linear lamp embodiments, any suitable manufacturing procedure can be employed to fabricate the lamp assembly. For example, a screen printing can be used to directly print ink onto the surface of the lens. A printing process. Other printing techniques can be used to print and/or coat the phosphor, such that a roller coater is used to apply the phosphor ink to the lens. Spray coating can be used in another technique for applying phosphors to lenses. Lamination can also be performed to make a linear lamp. In this method, a single sheet of phosphor material is produced, for example with or without a clear carrier layer. The phosphor sheet is then laminated to the optical lens/tube structure. A co-extrusion procedure can be performed to make a linear lamp configuration. Two extruders can be used to feed into a single tool to form both the phosphor layer and the material of the lens, wherein the two layers are formed simultaneously and fabricated together in this method. If the chamber in the lens contains a solid optical medium, a co-extrusion method can be used to make three layers with three extruders.

In some embodiments, a multilayer optical component is provided that integrally includes a phosphor portion, a lens, and a reflector portion. The multilayer optical assembly can be fabricated using a triple extrusion process in which three extruders are used to feed into a single tool to form the phosphor layer, the material of the lens, and the material of the reflector. The three extruders are used to feed into a single tool to form three separate layers of material, including the phosphor, the material of the lens, and the material of the reflector. The three layers are simultaneously formed and fabricated together in this method. This method can be combined with a wide variety of source materials (eg PC-polycarbonate, PMMA-poly(methyl methacrylate) and PET-polyethylene terephthalate) containing most or all of the thermoformed plastics. use. This triple extrusion procedure can generally use pellets of the same or similar pellets for injection molding materials. If the chamber in the lens contains a solid optical medium, a quadruple extrusion process can be used to make multiple layers with four extruders.

In some embodiments, a circuit board having an array of LEDs is mounted to and in thermal communication with a support body. The reflector is formed with a lower flange portion extending away from a central portion of the multilayer optical assembly. The flange portion is configured to be placed into a slot in one of the channels of the support body.

In certain embodiments, a co-extrusion process is performed using a multilayer optical component having an array of LEDs 22 , wherein the LED 22 is attached to one of the structures fed to the co-extrusion device such that the multilayer optical component is attached to it as it is formed A circuit board with LEDs.

The inner chamber of the lamp can be filled with an optical medium. The optical medium within the chamber includes a material (eg, a solid material) having a refractive index that closely matches the phosphor, one of the refractive indices of the LED, and/or any type of encapsulation that may be present on top of the LED material. The optical medium can be selected from any suitable material (eg, polyoxyl) that is generally attributed to the phosphor or LED material or that matches the refractive index of the materials, and/or any encapsulating material used to surround the LED. . If the chamber in the lens contains a solid optical medium, a co-extrusion process can be used to fabricate the multilayer optical component to include an optical medium, for example, by adding an extruder to the material used in the optical medium.

A light diffusing/scattering material can be used in conjunction with the multilayer optical component. The light diffusing/scattering material is useful for reducing the amount of phosphor material required to produce a selected color of emitted light. The light diffusing/scattering material is also useful for improving the white appearance of the off state of the lamp. The light diffusing/scattering material can be included into any of the layers of the multilayer optical device. For example, the light diffusing/scattering material can be incorporated into a layer containing a phosphor, added to a lens, included as a completely separate layer, or any combination of the above.

In any of the disclosed embodiments, the combination of the solid optical medium and the phosphor can be replaced by a layer of material that completely fills the volume surrounding the LED, but also includes phosphorescence that is entirely within the layer of material. body. This provides a hybrid remote phosphor/non-distal phosphor method whereby the phosphor is located in the material layer filling the internal cavity, but some phosphors are located in close proximity to the LED (in the portion of the material adjacent to the LED) ), but most of the phosphor is actually quite far from the LED (in a portion away from the material of the LED). Thus, this approach provides many of the advantages of remote phosphor design while also maximizing light conversion efficiency (due to the elimination of refractive index mismatch based on the elimination of the air interface). Manufacturing can also be cheaper and easier because the extrusion process and apparatus only need to extrude a single layer of material, rather than an extruder for the phosphor material and a separate extruder for the optical media material.

Some embodiments include a reflector having one of the high sidewalls. The side walls are for focusing It is useful to emit light from a lamp into a desired direction.

According to some embodiments, one or more linear illumination configurations are placed inside an envelope to form a replacement for a standard incandescent bulb. The lamp can include a standard electrical connector (eg, a standard Edison type connector) that allows the lamp to be used in conventional lighting devices. The linear illumination configurations are vertically oriented and extend axially within the lamp. Internally, the LEDs within the linear illumination configurations are radially oriented from the central axis of the lamp. This configuration provides a good overall emission pattern from one of the lamps over a wide range of emission angles, wherein the exact dimensions (e.g., length, width) of the linear illumination configuration are selected to provide a desired emission profile. The envelope can be configured in any suitable shape. In some embodiments, the envelope comprises a standard bulb shape. This permission light is used in any application/location that can be implemented in other ways by means of a standard incandescent light bulb. The envelope may comprise or be used in conjunction with a diffuser. In some embodiments, the scattering particles are provided at the envelope as an additional layer of material or directly incorporated within the envelope material.

Inline testing using any of the above methods can be employed to control and minimize variations in the final manufactured product. With a co-extrusion system, one possible method of performing in-line testing is to install the colorimeter or spectrometer when one of the color meter or spectrometer is actively squeezed. This metrology tool will typically be installed in-line after the cooling bath and dryer but before cutting. The color measurement provides instant feedback of the extrusion system that adjusts the layer thickness by varying the relative pressure of the two extrusion screws. The phosphor layer is made thicker or thinner to instantly tune the color of the product as it is squeezed. This allows for a single classification accuracy while enabling quality checks to be performed instantly during the extrusion process. Similar in-line testing can be used with printing and coating methods.

In some embodiments, the length L ₁ of the outer surface of the lens exceeds the length L ₂ of the surface of the phosphor portion. In some methods, the length L ₁ is at least twice as large as L ₂ .

An optical assembly can include a cylindrical body having an axial length of one and a radius r, having a hemispherical end and mountable to a flat end of an LED package, wherein the phosphor provides On the cylindrical surface and the hemispherical surface of the assembly. In some embodiments, the aspect ratio is 3:1 (although other ratios may be employed in certain embodiments).

In accordance with certain embodiments of the present invention, SQE loss is substantially eliminated or reduced by implementing some or all of the following factors into a lamp design: (i) a remote phosphor; (ii) a coupling optics a device; and (iii) a phosphor wavelength conversion layer having an aspect ratio greater than 1:1.

Additional details of aspects, objects, and advantages of the invention are set forth in the description and claims. The foregoing description of the preferred embodiments of the invention are intended to

2‧‧‧Lighting diode

4‧‧‧Light Emitting Diode Wafer

6‧‧‧Plastic or metal reflector cup/cup

8‧‧‧Epoxy resin

10‧‧‧ lens

20‧‧‧Lighting diode lighting configuration / lighting configuration

21‧‧‧Linear lighting configuration/Linear lamp/Linear lamp/light based on LED

22‧‧‧Light Emitting Diode/Light Emitting Diode Wafer

23‧‧‧Inside indentation/indentation/groove

24‧‧‧Stainless steel case/reflector cup/shell

25‧‧‧Printed circuit board/board/flex circuit board

26‧‧‧Convex lens/lens/substantially spherical solid lens/optical component/elongated lens

27‧‧‧Light extraction cover/encapsulation material

28‧‧‧flat surface

29‧‧‧End plate/end cap

30‧‧‧ Phosphor layer/phosphor/elongated phosphor layer/phosphor moiety

31‧‧‧Light diffusing layer/light scattering material/separate layer/light diffusing material

32‧‧‧Outer convex surface

33‧‧‧Internal/indoor/room/internal chamber/cavity/internal volume

34‧‧‧ inner surface

36‧‧‧Spherical surface

38‧‧‧ outer spherical surface

40‧‧‧Inside curved surface

42‧‧‧Outer curved surface

44‧‧‧ spherical surface

50‧‧‧Reflective material/reflector/part/reflector part

52‧‧‧Reflective material/reflective layer/coating

54‧‧‧ radiator / support body

56‧‧‧Optical media

60‧‧‧Standard electrical connector

62‧‧‧Envelope/envelope material

100‧‧‧ lights

d‧‧‧Total diameter/diameter

L‧‧‧ Length

L ₁ ‧‧‧ length

L ₂ ‧‧‧ length

R‧‧‧ Radius

1 is a schematic representation of one of the conventional white LEDs; FIG. 2 to FIG. 7 are schematic representations of an LED illumination configuration; FIG. 8 is an LED linear illumination configuration according to one embodiment of the present invention. 1 to 12 are schematic representations of an LED linear lamp illumination configuration in accordance with an embodiment of the present invention; and FIG. 13 is an end view of one of the LED linear lamp illumination configurations in accordance with an alternative embodiment of the present invention; 14A and 14B based end view of an additional embodiment of a linear configuration of LED lighting embodiment; FIGS. 15 to 17 lines of a schematic configuration of a linear LED lighting scattering particles expressed; FIG. 18 one system having a chamber interior LED lighting one exemplary cross-sectional view showing a schematic configuration; FIG. 19 one of the LED lighting system having a configuration inside a chamber and one oval cross-sectional view schematically showing a lens shape; FIGS. 20 to 22 lines of scattering particles having an alternative linear LED lighting Disposing Figure 23 is a schematic end view of an LED linear lamp assembly; Figure 24 is a diagram of an emission pattern of an exemplary lamp using one of the components of Figure 23 ; Figure 25 is an LED linear lamp assembly An illustrative end view FIG line 26 using one of the assembly of Figure 25, one exemplary example of the lamp emission pattern drawings; FIG. 27A, one LED-based lighting linear configuration wherein one of the functions of the collimator lens provides a schematic representation; FIG. 27B based an alternate One of the LED linear light illumination configurations is schematically illustrated; FIG. 28 is an end view of an LED linear light assembly in which a particular aspect ratio is provided; FIG. 29 illustrates one of the multilayer optical assemblies in accordance with some embodiments of the present invention. End view of the lamp; Figure 30 illustrates an end view of a lamp having a multilayer optical assembly in which an optical medium is placed indoors; Figure 31 illustrates an end view of a lamp having a multilayer optical component, the multilayer optical The assembly further includes scattering particles; Figure 32 illustrates an end view of a lamp having a multilayer optical component in which one of the optical media placed within the chamber comprises a photoluminescent material; and Figure 33 illustrates a lamp having a multilayer optical component The end view, wherein the reflector comprises a high wall; and Figures 34 and 35 are perspective views of an LED lamp having a vertically oriented linear illumination configuration.

For a better understanding of the present invention, embodiments of the present invention will now be described by way of example only.

Referring to Figure 2, there is shown for generating light of a selected color (for example white light), one LED lighting configuration 20. Illumination configuration 20 includes an LED wafer 22 that is preferably operable to produce a gallium nitride wafer that is preferably light having a wavelength in the range of 300 nm to 500 nm. The LED wafer 22 is mounted inside a stainless steel housing or reflector cup 24 having metallic silver deposited on its inner surface to reflect light toward the output of the illumination configuration. A convex lens 26 is provided to focus the light output from the configuration. In the illustrated example, lens 26 is substantially hemispherical in form. Lens 26 can be made of a plastic material (such as polycarbonate, acrylic, polyfluorene oxide) or glass (such as cerium oxide-based glass) or any material that is substantially transparent to the wavelength of light produced by LED wafer 22 .

In FIG. 2 , lens 26 has a flat (substantially flat) surface 28 provided thereon with a phosphor layer 30 prior to mounting the lens to outer casing 24 . Phosphor 30 can include any photoluminescent material such as a nitride and/or sulfate phosphor material, oxynitride and oxysulfate phosphor, garnet material (YAG) or a quantum dot material. A phosphor, typically in the form of a powder, is mixed with a binder material (such as an epoxy or a polyoxyl resin) or a transparent polymeric material and the mixture is then applied to the surface of the lens to provide a phosphor layer 30 . The mixture can be applied by brushing, dropping or spraying or other deposition techniques that will be readily apparent to those skilled in the art. Furthermore, the phosphor mixture preferably further comprises a light diffusing material such as titanium oxide, cerium oxide or aluminum oxide to ensure a relatively uniform light output.

The color of the light emitted from the illumination arrangement can be controlled by appropriate selection of the thickness of the phosphor composition and the thickness of the phosphor layer and/or the weight of the phosphor. The thickness of the phosphor layer and/or the weight loading of the phosphor will be determined to be derived from phosphorescence. The ratio of the output light of the body. To ensure a uniform output color, the phosphor layer is preferably of uniform thickness and has a typical thickness in the range of from 20 μm to 500 μm.

One advantage of such illumination configurations is that there is no need to incorporate the phosphor into the encapsulating material in the LED package. Moreover, the color of the light output by the configuration can be easily changed by providing a different lens having one of the appropriate phosphor layers. This enables mass production of a common laser package. In addition, this lens provides direct color conversion in an LED illumination configuration.

Referring to FIG. 3 , another LED illumination configuration 20 is shown in which the phosphor 30 is provided as a layer on the convex surface 32 outside of the lens 26 . In this embodiment, the lens 26 is dome-shaped in form.

4 shows an LED illumination configuration 20 in which lens 26 includes a substantially hemispherical housing and phosphor 30 is provided on inner surface 34 of lens 26 . The phosphor lines are provided in the inner surface of one of the advantages, the lens 26 and provides environmental protection for the LED and the phosphor. Alternatively, the phosphor can be applied as a layer (not shown) on the outer surface of the lens 26.

FIG. 7 shows an LED illumination configuration 20 in which the optical assembly includes a substantially spherical solid lens 26 and the phosphor is provided on at least a portion of the spherical surface 44 . In a preferred configuration, as illustrated, the phosphor is applied to only a portion of the surface, which is then mounted within the volume defined by the outer casing. By providing the lens 26 in this manner, this provides environmental protection for the phosphor 30 .

5 illustrates an LED illumination configuration 20 in which lens 26 (optical assembly) includes a substantially spherical housing and phosphor 30 is deposited as one of inner spherical surface 36 or at least a portion of outer spherical surface 38 and LED wafer 22 is mounted. Within the spherical housing. To ensure uniform radiation emission, a plurality of LED wafers are advantageously incorporated, wherein the wafers are oriented such that they each emit light in different directions. This form is preferred as a light source for replacing an existing incandescent light source (bulb).

Referring to Figure 6 , a further LED illumination configuration 20 is shown in which the optical assembly 26 includes a hollow cylindrical form and the phosphor is applied to the inner curved surface 40 or the outer curved surface 42 . In this configuration, the laser wafer preferably includes an array of linear laser wafers disposed along the axis of the cylinder. Alternatively, lens 26 can include a solid cylinder (not shown).

FIG Example 6 illustrates the substantially linear illumination configuration / linear lamp 21 one example, linear illumination configuration / linear lamp 21, one line typically has a long tubular contour lighting apparatus. These lamps are common in many office or work space environments, and many commercial and public buildings will conventionally incorporate lighting fixtures and ceiling recesses/grooves in the ceiling to assemble standard-sized linear lamps (such as standard tubulars). T5, T8 and T12 lights).

Linear lamps are typically implemented by means of fluorescent tube technology, which uses electricity to A gas discharge lamp that excites mercury vapor. However, there are many disadvantages associated with the use of fluorescent-based lamps. For example, mercury in fluorescent lamps is considered toxic, and damage to fluorescent lamps (especially in pipes or airways) may require expensive cleaning to remove the mercury (as recommended by the Environmental Protection Agency). Moreover, the manufacture of fluorescent lamps can be quite expensive, in part due to the requirement to use a ballast to regulate the current in such lamps. In addition, fluorescent lamps have a relatively high defect rate and a relatively low operating life.

In contrast, LED-based linear lamps overcome these problems associated with fluorescent lamps. Unlike fluorescent lamps, LED-based linear lamps do not require any mercury. Compared to fluorescent lamps, LED-based lamps are capable of producing higher lumens per watt, while having lower defect rates and higher operational life expectations.

The method illustrated in Figure 6 provides a configuration in which light generated by a linear lamp is emitted in all directions. The phosphor layer 30 and the lens / optical assembly 26 completely surrounds a linear array of LED 22. Thus, the light produced by the lamp is emitted in a full 360 degree direction with one of the central axes of the lamp.

Figure 8 illustrates an LED-based linear lamp 21 in which light is emitted from the linear lamp in a selected direction, in accordance with an embodiment of the present invention. The array of LED chips 22 is mounted on a support (e.g., a printed circuit board 25 ) within the inner indentation 23 that is mounted on the lens 26 . An internal cavity / chamber 33 is formed in the inside of the lens 26. The wall of chamber 33 contains a phosphor layer 30 . In some embodiments, LED wafer 22 includes a gallium nitride wafer that is operable to produce light, radiation, preferably at a wavelength in the range of 300 nm to 500 nm. The surface of the circuit board 25 may be formed or covered with a reflective material 52 to direct light from the LED wafer 22 away from the circuit board 25 and toward the phosphor 30 .

Each of the LEDs in the array of LED dies 22 can be covered or otherwise encapsulated by a light extraction cover 27 . The light extraction cover 27 reduces an excessive mismatch between the refractive index of the LED 22 and the refractive index of the air within the interior chamber 33 . Any mismatch in refractive index can result in a significant portion of the LED light from the total LED light output loss. By including the light extraction cover 27 , this helps to reduce excessive mismatch in refractive index, thereby contributing to an increase in one of the overall light conversion efficiencies of the lamp 21 .

The light emitted by the LED chip 22 is converted into photoluminescence light by the phosphor 30 . The final light emission output of the color quality based (at least partially) any combination of the remaining light of the wavelength of the LED chip 22 based on the wavelength of the emitted light 30 actuated by emission of light from the phosphor and the phosphor 30 by the. The color of the light emitted from the illumination arrangement can be controlled by appropriate selection of the thickness and/or loading density of the phosphor composition and the phosphor within the phosphor layer. The thickness and/or load density of the phosphor will be determined from the phosphor. The ratio of the output light. To ensure a uniform output color, the phosphor layer is preferably of uniform thickness and has a typical thickness in the range of from 20 μm to 500 μm.

The actual pattern of light emitted from the lamp 21 is affected by the configuration of the lens 26 . In the current embodiment of lens 26 having a semicircular profile, the semicircular profile (e.g.) for the coverage of one substantially corresponds to the central axis of one of the lenses 26 permits radial angle of the light along a desired direction from the lamp 21 The focus and distribution of the emitted light from the output. Lens 26 can be made of any suitable material, such as a plastic material (such as polycarbonate) or glass (such as cerium oxide-based glass) or any material.

The distribution of light from the lamp 21 is also affected by the shape of the phosphor 30 in the chamber 33 . The lamp 21 shown in Figure 8 has a phosphor 30 that enhances one of the conical profiles of the amount of light distributed from the sides of the lamp 21 . Figure 13 illustrates an alternative design in which the phosphor 30 has one of the contours of a semi-circular shape that is not as conical as it is. This method provides a relatively large light distribution towards the center of the distribution area. The exact shape of phosphor 30 and/or lens 26 can be selected and combined to provide any suitable output pattern and distribution as desired.

Chamber 33 is provided in a cavity (also referred to herein as a "mixing chamber") within lamp 21 having a volume that is sufficiently large to insert LED 22 into the cavity. This permits LED 22 to be located wholly or partially within the interior of lens 26 and/or phosphor 30 .

In the method of Figure 8 , the indentation/groove 23 is incorporated into the outer contour of the lens 26 to accommodate direct placement of the PCB 25 or on-wafer (COB) array. In the method of Figure 14 , a slot formed in lens 26 permits PCB 25 to slide and support into the slot. The PCB or COB surface has a reflective layer or coating 52 placed thereon to reflect the light emitted by the LED toward the phosphor 30 . The bottom surface of lens 26 may also be covered with a reflective material 50 . The method of implementing a cavity/chamber 33 within lens 26 contributes to an extremely simple assembly and improved efficiency due to avoiding losses from an external mixing chamber.

One benefit of this configuration is that the chamber provides for mixing light with minimal loss in a highly transparent solid body. An example of this occurs when a lamp contains both red and blue LEDs in the chamber, and the chamber allows light from such LEDs (eg, red light) to be evenly distributed inside the lens. There are various reasons for the advantages provided by the internal mixing chamber. For example, one reason is to provide cross-wall light emission due to the configuration of the internal mixing chamber. Even if the reflector is still provided on the "base" of the lamp, most of the light moving through the mixing chamber will traverse from one wall of the phosphor to the other without reflection from the reflector, thus producing light for the lamp Improve its efficiency. Another benefit provided by this configuration is that it removes the point source effect of having individual LEDs in the lamp. Each LED is a point source of light (eg, blue or red light), but since the LED is in a chamber whose walls are covered with a phosphor, the light emitted by the phosphor will significantly obscure the point source effect of the LED. Yet another advantage is the directionality provided by the current configuration. Since most fluorescent replacement lamps will be inserted into the ceiling or wall fixture, it is likely that the emitted light will be provided in a desired direction (eg, away from the ceiling or wall). This embodiment, configured using a lens and an internal chamber, enhances the directivity of the emitted light in a desired direction. Another benefit provided by embodiments of the present invention is that the amount of phosphor required to manufacture the lamp can be minimized for a given size of lamp. Even though the outer dimensions of the lamp can be quite large due to the size of the lens, the smaller surface area of the interior chamber also means that a much smaller amount of phosphor is actually required for the lamp. Yet another benefit of the small interior chamber is that it reduces the apparent size of the phosphor assembly when viewing the lamp in an off state.

Having the optical material of lens 26 with a clear or transparent property also provides the benefit of forming a linear optic/linear lens. Alternatively, the lens can be configured to operate to provide a collimated light pipe at the source such that light travels an extended distance inside the tube without leaving the side. For example, Figure 27A shows one of the lamps in which the optical assembly 26 is configured with a suitably curved side to provide collimation functionality. In this configuration, the light emitted from the phosphor 30 that strikes the wall of the lens 26 at a particular angle will be reflected away from the walls in a downward direction, for example, based at least in part on the light pipe effect of the lens 26 . This result can be achieved without the need to include reflective material 50 on the walls of lens 26 , but the inclusion of reflective material 50 will improve the efficiency of emitting light in a downward direction.

FIG. 27B shows an alternate embodiment of a lamp 21 in which the lens 26 is not configured to extend along the entire length of the reflector 50 . Rather, lens 26 generally forms a curved or dome-like shape that only partially fills one of the interior volumes formed by reflector 50 . The proper configuration of lens 26 and reflector 50 permits this method to form a direct lamp replacement having any desired light emission characteristics. In both the method of Figure 27A and the method of 27B , a co-extrusion process can be used to fabricate the phosphor layer, lens and reflector structures.

In the embodiment of Figure 8 , the light is typically unstructured without a collimator. However, the current embodiment forms a linear lens optic having one of the clearing materials coupled to a smaller linear source (phosphor layer). The combined system allows for accurate control of the light distribution pattern with minimal loss due to the absence of an air interface between the distal phosphor layer and the optics. The cross-section in the figure shows a light source and a single optical device that are coupled together into a single unit. It is possible to configure a particular linear beam pattern by designing the shape of the linear lens relative to the source. In fact, lens 26 can be used to shape the emitted properties of the light produced by the lamp, for example, by focusing the light emitted from the lamp.

In some embodiments, further operational efficiency of the lamp is provided by including an optical medium within chamber 33 . The optical medium within chamber 33 includes a material (eg, a solid material) having a refractive index that is more closely matched to phosphor 30 , one of the refractive indices of LED 22 , and/or any type that may be present on top of LED 22 . Encapsulation material. One reason for using this optical medium is to eliminate the air interface present between the LED 22 and the phosphor 30 . The problem solved by this embodiment is that there is a mismatch between the refractive index of the material of the phosphor 30 and the refractive index of the air within the internal volume 33 of the lamp 21 . This mismatch in the refractive index of the interface between the air and the lamp assembly can result in a significant portion of the light being lost in the form of heat generation. Thus, a relatively small amount of light and an excessive amount of heat is generated for a given amount of input power. By having chamber 33 filled with an optical medium 56 , this method permits light to be emitted into, within, and/or through the volume of the lamp without necessarily causing an excessive mismatch in refractive index from an air interface. Loss. The optical medium 56 can be selected from any material that is generally within the material of the phosphor 30 , the LED 22 , or a material that matches the refractive index of the materials (eg, polyoxyn), and/or any pocket surrounding the LED 22 . Sealing material. An exemplary embodiment of the implementation of an optical medium is set forth in the U.S. Provisional Application Serial No. 61/657,702, filed on Jun. 8, 2012, entitled <RTI ID=0.0>> Additional details of the method are hereby incorporated by reference in its entirety.

Figures 9 , 10 , 11, and 12 provide an illustration of the components of a linear lamp 21 in accordance with a particular embodiment of the present invention. Figure 9 is an end view of the linear lamp 21 and Figure 12 is an exploded end view of the linear lamp 21 . Figure 10 is an exploded perspective view of one of the lamps 21 , which is further enlarged in Figure 11 . Linear lamp 21 comprises a chamber 26 having the same length of one lens is integrally formed of one lens 26 33 elongation. Chamber 33 is shaped to provide a desired light distribution pattern. In this current example of linear lamp 21 , cavity 33 is shown to have a dome-shaped profile. A phosphor layer 30 is placed in chamber 33 .

A linear array of LEDs 22 is located on a circuit board 25 . The LED 22 array can be implemented in any suitable manner. For example, an array of LEDs can be implemented using an on-board wafer (COB) configuration. A reflective material 52 (eg, a reflective strip or paper) is provided that includes one of the apertures for the LEDs 22 . The circuit board 25 is mounted to a heat sink 54 . 54 includes a heat sink, a circuit board assembly 25, and a reflective material 52 to be set to one of the concave lens 26 of the end portion 29 of the end plate 26 is attached to the lens. 29 includes a set of four screw holes of the end plate (not shown in FIG. 9). The top two screw holes are used to insert the screw into the opening in the lens 26 . The bottom two screw holes are used to insert the screw into the opening in the heat sink 54 .

In embodiments in which the linear lamp 21 is intended to be a direct replacement for a standard fluorescent lamp such as a t5, T8 or T12 fluorescent tube, a suitable connector including a G5 or G13 double pin connector is provided for assembly to a standard firefly. An end cap (not shown) in the light fixture. An external reflector (not shown) can also be used in conjunction with the lamp 21 to direct the output light from the lamp 21 into the desired direction. The orientation direction of the lamp 21 will be adjusted as appropriate. For example, a lamp, when mounted in a ceiling fixture, will typically be guided in a downward direction (eg, where lens 26 faces down under a reflector).

The bottom portion of lens 26 is configurable to adjust the illumination pattern of lamp 21 , for example, by adjusting the radial coverage angle of lens 26 as measured from one of the central axes of the lamp. If the contour of the lens and extending over the full one of a central axis 360, then this will lead to a lamp with a 360-degree radiation, e.g., FIG. 6 of the lamp shown. The angle of the bottom portion of the lens can also be adjusted to adjust the illumination pattern of the lamp. 14A illustrates an end view of an embodiment of the present invention in which the bottom portion of lens 26 is configured such that lens 26 provides a semicircle having a radial angle that is slightly greater than one of 180 degrees with respect to a central axis of lamp 21 . The profile, for example, wherein portion 50 is tilted in an outward direction to improve the propagation of light emitted by the lamp. An alternate embodiment can be configured such that the bottom portion of lens 26 is tilted in an inward direction. 14B illustrates an end view of an embodiment of the present invention in which the bottom portion of lens 26 is configured such that lens 26 provides a semicircle having a radial angle that is slightly less than one of 180 degrees with respect to a central axis of lamp 21 . The profile, for example, wherein portion 50 is inclined in an inward direction to improve the concentration of light emitted by the lamp in a selected direction.

One problem associated with LED lighting devices that is addressed by embodiments of the present invention is the non-white color appearance of the device in an off state. During an on state, the LED wafer or die produces blue light and thereafter some portions of the blue light are absorbed by the phosphor to re-emit yellow light (or green and red, green and yellow, green and orange) Light or a combination of yellow and red light). The portion of the blue light generated by the LED that is not absorbed by the phosphor is combined with the light emitted by the phosphor to provide light that is approximately white in color to the human eye. However, in an off state, the LED wafer or die does not produce any blue light. Rather, the light generated by the remote phosphor illumination device is based, at least in part, on external light (eg, daylight or room light) that excites the phosphor material in the wavelength conversion component and thus produces a photo in the photoluminescent light. Yellowish, yellowish orange or orange in color. Since the LED wafer or die does not produce any blue light, this means that there will be no yellow/orange light to be combined with the photoluminescent light from the wavelength conversion component (eg, phosphor 30 ) to produce any white light that looks like Residual blue light. Therefore, the lighting device will appear yellowish, yellowish orange or orange in color. This may be desirable for a potential purchaser or consumer who appears to be white light.

According to the embodiment of Fig. 15 , a light diffusing layer 31 provides the benefit of solving this problem by improving the visual appearance of the device in an off state for an observer. To some extent, since the light diffusing layer 31 comprises particles of a light-diffusing material, the particles of a light-diffusing material can be substantially reduced to otherwise cause the wavelength converting component to re-emit with a yellowish/orange color. The passage of external excitation light of one wavelength of light. For example, one of the light-diffusing materials in the light-diffusing layer 31 is selected to have a size range that increases the probability of its scattered blue light, which means that less external blue light passes through the light-diffusing layer to excite the wavelength-converting layer. . Thus, the remote phosphor illumination device will have a more white appearance in an off state due to the fact that the wavelength conversion component emits less yellow/red light.

The light diffraction particle size can be selected such that the particles will scatter blue light (eg, at least two times) than the light produced by the phosphor material that it will scatter. The light diffusing layer ensures that during an off state, the light diffracting material is scattered and guided by the device to receive a higher proportion of external blue light away from the wavelength conversion layer, thereby reducing the external The probability that the source photons interact with a phosphor material particle and minimizes the generation of yellow/orange photoluminescence light. However, during an on state, light produced by the phosphor from the excitation light from the LED source may still pass through the diffusion layer with a low probability of scattering. Preferably, to enhance the white appearance of the illumination device in an off state, the light diffraction material within the light diffusion layer has one of the "nano particles" of one of the average particle sizes of less than about 150 nm. For light sources that emit light of other colors, the nanoparticles may correspond to other average sizes. For example, for a UV light source, the light diffraction material within the light diffusing layer can have an average particle size of less than about 100 nm.

Therefore, by appropriately selecting the average particle size of the light scattering material, it is possible to configure the light diffusion layer such that it makes the excitation light (for example, blue light) more than other colors (ie, green light and red light emitted by the photoluminescent material). Easily scatter. For example, blue light (450 nm to 480 nm) scattered by TiO ₂ particles having an average particle size of 100 nm to 150 nm may be twice as large as green light (510 nm to 550 nm) or red light (630 nm to 740 nm) to be scattered. the above. As another example, TiO ₂ particles having an average particle size of 100 nm will scatter the blue light by nearly three times (2.9 = 0.97 / 0.33) of the scattered green or red light. For TiO ₂ particles having an average particle size of 200 nm, these TiO ₂ particles will scatter the blue light more than twice (2.3 = 1.6/0.7) of the scattered green or red light. According to some embodiments of the invention, the light diffraction particle size is preferably selected such that the particles will scatter the resulting blue light by at least two times the light produced by the phosphor material. .

Another problem with remote phosphor devices that can be addressed by embodiments of the present invention is that the emitted light varies with the color of the emission angle. This problem is often referred to as COA (Color Over Angle). The distal phosphor layer allows a specific amount of blue light to be emitted as a blue component of white light. This is from the directional light of the LED. The RGY (red greenish yellow) light from the phosphor is Lambertian. Therefore, the directivity of blue light can be different from the directionality of RGY light that causes a "halo" effect at the edge, where the color is blue The direction of the LED light appears to be "cooler" and appears "warm" at the edge of the entire RGY of the light system. The addition of a nano diffuser selectively diffuses the blue light such that it has the same Lambertian pattern as the RGY light and forms a very uniform angular color. Conventional LEDs also have this problem that can be improved by using remote phosphors using this technology. Far-end phosphor devices typically suffer from perceived color non-uniformities when viewed from different angles. Embodiments of the present invention correct this problem because the addition of a light diffusing layer in direct contact with the wavelength converting layer significantly increases the color uniformity of the emitted light with the emission angle θ.

Embodiments of the present invention can be used to reduce the amount of phosphor material required to fabricate an LED lighting product, thereby accounting for the relatively expensive nature of the phosphor material and reducing the cost of manufacturing such products. In particular, the addition of a light diffusing layer comprised of particles of a light-diffusing material can substantially reduce the amount of phosphor material required to produce a selected color of emitted light. This means that a relatively small amount of phosphor is required to fabricate a wavelength conversion component as compared to comparable prior art methods. Therefore, it would be much less costly to fabricate lighting devices that employ such wavelength conversion components, particularly for remote phosphor illumination devices. In operation, the diffusion layer increases the probability that a photon will result in the generation of photoluminescent light by reflecting the light back into the wavelength conversion layer. Thus, the inclusion of a diffusion layer and a wavelength converting layer reduces the amount of phosphor material required to produce a given color emitting product, for example, by up to 40%.

Figures 15 , 16 and 17 illustrate different methods of introducing a light scattering material into an LED lamp that substantially reduces the amount of phosphor material required to produce a selected color of emitted light. Additionally, a light diffusing layer can be used in conjunction with additional scattering (or reflecting/diffractive) particles in the wavelength conversion component to further reduce the amount of phosphor material required to produce a selected color of emitted light. FIG 15 illustrates a light scattering material 31 which comprises in one method in a single layer. FIG. 16 illustrates one method in which the light scattering material 31 is contained within a layer containing the phosphor 30 . FIG. 17 illustrates an alternative method in which light scattering material 31 is introduced into lens 26 . Any combination of the above methods can also be implemented. For example, light scattering material 31 can be introduced into both phosphor layer 30 and lens 26 . Additionally, the light scattering material can be included in both a single layer 31 and a phosphor layer 30 . Further, a light scattering material 31 may be included in each of the individual layer, the phosphor layer 30, and the lens 26 .

An alternative approach can be taken to improve the white appearance of the off state of the lamp. For example, texture can be incorporated into the exterior surface of the lamp, for example, in the outer surface of lens 26 to improve the off-state white appearance of the lamp.

Yet another possibility is to implement a white thin layer just after the yellow phosphor layer and before clearing the linear optics. This three-layer structure will have a white appearance in the off state, but the primary optics will still be clear (non-diffusing/blurred). This method has the benefit of maintaining the light distribution pattern of the linear lens optics while still providing a white appearance.

Further details regarding an exemplary method of implementing scattering particles are set forth in U.S. Patent Application Serial No. 11/185,550, the entire disclosure of which is incorporated herein in The application is hereby incorporated by reference in its entirety.

The method of using an internal cavity as a "mixing chamber" can also be applied to a non-linear lamp. Figure 18 shows an LED illumination arrangement 20 in which the lens 26 includes a solid hemispherical shape in accordance with an embodiment of the present invention. The LED wafer 22 is mounted within the chamber 33 of the illumination arrangement 20 such that it is completely contained within the interior of the outline of the phosphor 30 . An indentation 23 is formed in the lens 26 to receive the PCB 25 .

Lens 26 can be fabricated to provide any suitable shape as desired. For example, Figure 20 shows an alternative to an LED illumination configuration in accordance with one embodiment of the present invention in which lens 26 includes a solid oval shape. As before, the LED wafer 22 is mounted within the chamber 33 of the illumination configuration such that it is completely contained within the interior of the outline of the phosphor 30 . An indentation 23 is formed in the lens 26 to receive the PCB 25 .

Any of the earlier illustrated embodiments can be configured as a linear lamp. For example, the embodiment of Figure 2 shows a lamp having a convex lens 26 that is provided to focus light output from the configuration, wherein the lens 26 is substantially hemispherical in form. Lens 26 has a flat (substantially flat) surface 28 provided thereon with a phosphor layer 30 prior to mounting the lens to outer casing 24 . Figure 20 illustrates a linear lamp having a similar structure in a cross-sectional profile. The linear lamp includes an elongate lens 26 having a semi-circular cross-sectional shape, wherein the base of the lens 26 has a flat surface 28 on which an elongated phosphor layer 30 is provided. The LED 22 is mounted to a support surface where it is external to the lens 26 .

Similarly, the previously illustrated embodiment of FIG. 3 is directed to an LED illumination configuration in which phosphor 30 is provided as a layer on convex surface 32 outside of lens 26 . In this embodiment, the lens 26 is dome-shaped in form. Figure 21 illustrates a linear lamp having a similar structure in a cross-sectional profile. The linear lamp includes an elongated lens 26 having a contoured semi-circular shape, wherein the phosphor 30 is provided as a layer on the outer surface of the lens 26 .

The previously illustrated embodiment of FIG. 4 is directed to an LED illumination configuration in which lens 26 includes a substantially hemispherical housing and phosphor 30 is provided on the inner or outer surface of lens 26 . Figure 22 illustrates, in a cross-sectional profile, a linear lamp having a similar configuration, wherein the linear lamp includes an elongated lens 26 having a semi-circular housing profile, wherein the phosphor 30 is provided on the inner or outer surface of the lens 26 . One layer.

Figure 23 illustrates an exemplary configuration of one of the contours of a lamp in accordance with some embodiments of the present invention. The configuration of this figure shows a phosphor portion 30 having a tapered (or candle-shaped) cross-sectional shape within chamber 33 . When implemented as a T8 replacement lamp, the total diameter d = 25.54 mm (1 inch), l = 20.70 mm, h = 9.62 mm, and w = 8 mm. The length L ₁ of the outer surface of the lens 26 exceeds the length L ₂ of the surface of the phosphor portion 30 . In certain embodiments, L ₁ is at least twice as large as L ₂ . The surface area of the phosphor material is 10.5 in ² / ft.

Figure 24 is a diagram showing one of the emission patterns of light distributed by an exemplary embodiment of the lamp of Figure 23 . The dashed line shows an emission pattern that does not include an exemplary lamp of one of the lenses 26 . The solid line shows an emission pattern comprising an exemplary lamp of a lens 26 . As can be seen, the lens is used to shape the emitted light such that a large concentration occurs generally toward 0 degrees on the chart (toward the tip of the tapered shape of the phosphor portion 30 ).

Figure 25 illustrates another example configuration of a profile of a lamp in accordance with some embodiments of the present invention. The configuration of this figure shows one of the phosphor portions 30 having a generally dome cross-sectional shape within the chamber 33 . When implemented as a T8 lamp replacement, having a diameter d 1 inch (25.4mm), and wherein a length l = 20.70mm, and w = 8mm, same as the embodiment 23 of FIG. However, the value of h in this embodiment is 6 mm. As before, the length L ₁ of the outer surface of the lens 26 significantly exceeds the length L ₂ of the surface of the phosphor portion 30 , for example, where L ₁ is at least twice as large as L ₂ . The surface area of the phosphor material is 7.8 in ² / ft.

Figure 26 is a diagram showing one of the emission patterns of light distributed by an exemplary embodiment of the lamp of Figure 25 . The dashed line shows an emission pattern that does not include an exemplary lamp of one of the lenses 26 . 26 comprises one solid lines exemplary emission pattern of a light lens. As previously seen, the lens is used to shape the emitted light such that a large concentration is typically present toward 0 degrees on the chart (toward the tip of the dome shape of the phosphor portion 30).

These figures show a clear difference between the emission pattern of the lamp of Figure 23 and the emission pattern of the lamp of Figure 25 . The use of a dome shaped profile provides a more uniform pattern in the near field (at the tube surface or near the tube surface) light distribution and preferably in the far field beam control. The tapered cross-sectional shape of Figure 23 provides a greater distribution of light along the sides of the lamp. In contrast, a dome-shaped cross-sectional profile of Figure 25 towards the top of the lamp provides one of the larger light distribution. This highlights the ability to shape the light produced by the lamp by configuring the shape of the phosphor profile of the phosphor/chamber in the lens. The method of using a dome-shaped profile generally corresponds to a phosphor surface area that is smaller than the profile of the tapered shape, which potentially translates into a less costly lamp design.

The lamp configuration can also be configured to improve its light generation efficiency (also referred to herein as "system quantum efficiency" or SQE) and reduce SQE optical loss, where system quantum efficiency can be defined as the total number of photons produced by the system. The ratio of the number of photons produced by the LED. Many white LEDs and LED arrays are typically constructed of blue LEDs that are encapsulated with one of the particles containing a powdered phosphor material or an optical component (optical device) comprising one of the phosphor materials. )cover. Conventional white LED and LED array system quantum The efficiency (SQE) is not affected by the loss of the total light output of the lamp during the conversion of the blue LED light to white light, most of which is not due to the photoluminescence conversion procedure but to the subsequent emission into the LED. Absorption loss of light (both photoluminescence and LED light). Since the photoluminescence conversion process is isotropic, it will emit photoluminescent light in all directions and thereby generate up to about 50% of the photoluminescent light in one direction toward the LED, thereby causing LEDs Re-absorption and loss of photoluminescent light.

By appropriate configuration of the aspect ratio of the phosphor portion 30, may eliminate or significantly reduce the loss SQE lamp. The aspect ratio of the phosphor portion 30 is the ratio of the area of the phosphor layer to the area of the LED package. Figure 28 is an example of such a component comprising a cylindrical body having an axial length l and a radius r , having a hemispherical end and a flat end mountable to an LED package. Phosphors are provided on the cylindrical and hemispherical surfaces of the assembly. In this exemplary embodiment, the area of the LED package (i.e., the flat substrate of the component) is πr ² and the surface area of the wavelength conversion component (phosphor) is 2πr ² + 2πr1. Therefore, the aspect ratio is 2(r+1)/r:1. For a component in which the length l = 0.5r (i.e., its length in one axial direction is one of 1.5 times its diameter), the aspect ratio is preferably 3:1 (but in a particular embodiment Use other ratios). For this assembly, the solid optics within chamber 33 deliver most of the light to the opposite side of the phosphor optics and very little light is returned to the LED and package substrate. Traveling through solid optics does not have a refractive index change, so there is actually 100% efficiency. Therefore, the goal of this design is to maximize light emission by minimizing the amount of light returned to the LED package.

In accordance with certain embodiments of the present invention, SQE loss is substantially eliminated or reduced by implementing a combination of the following factors:

i) the remote phosphor-phosphor portion is separated from the LED;

Ii) A coupling optic - an optical material having a high refractive index material coupled directly to the LED and phosphor conversion assembly. This material should have a refractive index of 1.4 or greater (>1.5 preferred). Good optical coupling between blue LEDs and clear optics to ensure their effectiveness Acts as an optical transport layer. By eliminating the air interface and refractive index mismatch, virtually all of the light produced by the LED will travel to the wavelength conversion component (phosphor layer) with little or no loss.

Iii) A phosphor wavelength conversion layer-phosphor layer having an aspect ratio greater than 1:1 is separated from the blue LED by clear coupling optics. Ideally, the outer phosphor optics have the same refractive index as the clear layer and have no gaps or other optical losses in the interface with the clear optical. The phosphoric outer layer optic has an aspect ratio of 1:1 or greater than 1:1 such that the total surface area of the phosphor layer is coupled to the area of the LED package surface of the clear coupling optic except that it is in contact with the clear coupling optics At least three times.

In operation, the blue light travels through the clear coupling optics effectively without loss. When the blue light excites the phosphor layer, and the photoluminescent light can now travel in any direction as well due to the elimination of the optical medium/air interface. Due to the high aspect ratio of the photoluminescent wavelength conversion component, most of the light (both phosphor-generated and scattered LED light) will not travel back to the LED package. Rather, most of the light will travel through the clear optics to the other side and exit the phosphor layer on the opposite side. Once converted, YGR (yellow, green, red) light readily passes through the phosphor layer. In summary, when most of the light is in a standard LED configuration it no longer recirculates directly between the phosphor and the package/LED.

With regard to linear lamp embodiments, any suitable manufacturing procedure can be employed to fabricate the lamp assembly. For example, a printing process in which ink is printed onto the surface of the lens using screen printing can be employed. Other printing techniques can be used to print and/or coat the phosphor, such that a roller coater is used to apply the phosphor ink to the lens. Spray coating can be used in another technique for applying phosphors to lenses.

Lamination can also be performed to make a linear lamp. In this method, a single sheet of phosphor material is produced, for example with or without a clear carrier layer. The phosphor sheet is then laminated to the optical lens/tube structure.

A co-extrusion process can be performed to create a multi-layer linear illumination configuration. For two extruders It is fed into a single tool to form both the phosphor layer and the material of the lens. The two layers are simultaneously formed and fabricated together in this method. This method can be combined with a wide variety of source materials (eg PC-polycarbonate, PMMA-poly(methyl methacrylate) and PET-polyethylene terephthalate) containing most or all of the thermoformed plastics. use. This coextrusion process can generally use pellets of the same or similar pellets for injection molding materials. If the chamber in the lens contains a solid optical medium, a co-extrusion method can be used to make three layers with three extruders.

As described above, a slot can be incorporated into the outline of the extrusion to accommodate the PCB or COB array. The use of an internal cavity approach contributes to a simple assembly and improved efficiency due to avoiding losses from an external mixing chamber. In certain embodiments, the LEDs are mounted to a linear mixing chamber side and the extrusion is attached to the linear mixing chamber.

FIG 29 illustrates an end view of another embodiment of a lamp in accordance with certain embodiments of the present invention. The configuration of this figure shows a multilayer optical assembly that integrally includes a phosphor portion 30 , a lens 26, and a reflector portion 50 . As before, the phosphor portion 30 includes a generally dome cross-sectional shape of one of the surrounding chambers 33 . Lens 26 also includes an outer cross-sectional profile having a dome shape. The reflector 50 is formed of any material capable of substantially reflecting light and is intended to function by reflecting some or all of the light from the phosphor produced by the phosphor portion 30 away from the substrate of the lamp 21 . In certain embodiments, the reflector 50 comprises a white polycarbonate material.

A multilayer extrusion process can be utilized to fabricate a multilayer optical assembly in which three extruders are used to feed a single tool to form a phosphor layer, a material for the lens, and a material for the reflector. Three extruders are used to feed into a single tool to form three separate layers of material, including the phosphor, the material of the lens, and the material of the reflector. The three layers are simultaneously formed and fabricated together in this method. This method can be combined with a wide variety of source materials (eg PC-polycarbonate, PMMA-poly(methyl methacrylate) and PET-polyethylene terephthalate) containing most or all of the thermoformed plastics. use. This triple extrusion procedure can generally use pellets of the same or similar pellets for injection molding materials. If the chamber in the lens contains a solid optical For the medium, a quadruple extrusion method can be used to make multiple layers with four extruders.

In some embodiments, a circuit board 25 having an array of LEDs 22 is mounted to and in thermal communication with a support body 54 . The reflector 50 is formed with a lower flange portion extending away from a central portion of the multilayer optical assembly. The flange portion is configured to be placed into a slot in one of the channels of the support body 54 . This allows the lamp 21 to be easily mounted by mounting the support body 54 anywhere needed for a linear lamp by, and then attaching the multilayer optical assembly by sliding the flange portion into the appropriate passage in the support body 54 . Connected to the support body.

In an alternate embodiment, the lamp is not fabricated by first mounting the LED 22 to the circuit board 25 attached to the support body 54 . Rather, a co-extrusion process is used to fabricate one of the multilayer optical components having an array of LEDs 22 . In this embodiment, the LED 22 is attached to one of the flexible circuit boards 25 fed to the co-extrusion device such that the multilayer optical assembly is attached to the circuit board with the LEDs as it is formed.

Figure 30 illustrates an embodiment in which the chamber is filled with an optical medium 56 . The optical medium within chamber 33 includes a material (eg, a solid material) having a refractive index that is more closely matched to phosphor 30 , one of the refractive indices of LED 22 , and/or any type that may be present on top of LED 22 . The encapsulating material 27 . One reason for using optical media 56 , as previously described, is to eliminate the air interface present between LED 22 and phosphor 30 . This reduces and/or eliminates any mismatch between the refractive index of the material of the phosphor 30 and the refractive index of the air within the internal volume 33 of the lamp 21 . By reducing/preventing such mismatches in refractive index, this removal can result in a significant portion of the light being lost in the form of heat generated by the interface between the air and the lamp assembly. By having chamber 33 filled with an optical medium 56 , light is allowed to be emitted into, within, and/or through the volume of the lamp without necessarily causing loss due to excessive mismatch in refractive index of an air interface. . The optical medium can be selected from any suitable material (eg, polyoxyl) that is generally attributed to or in accordance with the refractive index of the materials typically used for phosphor 30 , LED 22 , and/or for surrounding any of LEDs 22 . Encapsulation material.

If the lens chamber 33 comprises a solid optical medium 56, a co-extrusion method can be used for producing a multilayer optical assembly (e.g.) by adding one of the materials used for an optical medium 56 of the extruder 56 also includes an optical medium. If the optical medium 56 includes a liquid material, the liquid material can be injected or inserted into the chamber 33 after the multilayer optical assembly has been mounted to the support body 54 . If desired, a curing process (e.g., using UV light) can be used to solidify the liquid material of optical medium 56 .

A light diffusing/scattering material can be used in conjunction with the multilayer optical component. The light diffusing/scattering material is useful for reducing the amount of phosphor material required to produce a selected color of emitted light. This light diffusing/scattering material is also useful for improving the white appearance of the off state of the lamp 21 .

The light diffusing/scattering material can be included into any of the layers of the multilayer optical device. For example, the light diffusing/scattering material can be incorporated into the layer containing phosphor 30 , added to lens 26 , included as a completely separate layer, or any combination. 31 shows an embodiment in which the light diffusing/scattering material 31 has been incorporated into the material of the lens 26 in the multilayer optical assembly.

In any of the disclosed embodiments, the combination of solid optical medium 56 and phosphor 30 can be replaced by a layer of material that completely fills the volume surrounding LED 22 , but also includes the entire layer of material. Phosphor inside. In FIG 32 illustrates this method. Here, the lamp 21 does not have a thin layer of a single phosphor. Rather, all of the internal volume surrounding the LED 22 is filled with a material that also includes the phosphor 30 . This provides a hybrid remote phosphor/non-distal phosphor method whereby the phosphor is located in the material layer filling the internal cavity, but some phosphors are located in close proximity to the LED 22 (inside the material adjacent to the LED) Medium), but most of the phosphor is actually quite far from the LED 22 (in a portion away from the material of the LED).

Thus, this approach provides many of the advantages of remote phosphor design while also maximizing light conversion efficiency (due to the elimination of refractive index mismatch based on the elimination of the air interface). Manufacturing can also be cheaper and easier because the extrusion process and the device only need to squeeze a single material. The layers, rather than an extruder, are used for the phosphor material and a separate extruder is used for the optical media material.

Figure 33 shows another embodiment in which the reflector 50 includes a high sidewall. These sidewalls are useful for focusing light systems that are emitted from the lamp 21 into a desired direction. However, these side walls 50 of the reflector can produce a desired light emitted from the lamp 21 in any manner desired by the configuration of the pattern.

Figure 34 illustrates an embodiment of a lamp 100 in which one or more linear illumination configurations 21 are placed inside an envelope 62 to form a replacement for a standard incandescent bulb. Likewise, the lamp 100 can include a standard electrical connector 60 (eg, a standard Edison type connector) that allows the lamp 100 to be used in conventional lighting devices.

The linear illumination configuration 21 is used as a lighting element in the lamp 100 . The linear illumination arrangement 21 is vertically oriented and extends axially within the lamp 100 with the end cap 29 placed at the end (eg, the distal end) of the linear illumination configuration 21 . Internally, the linear configuration of the LED lighting system 21 within the lamp 100 is oriented from the center of the shaft diameter. This configuration provides a good overall emission pattern from one of the lamps 100 over a wide range of emission angles, wherein the exact dimensions (e.g., length, width) of the linear illumination configuration 21 are selected to provide a desired emission profile.

Envelope 62 can be configured in any suitable shape. In some embodiments, the envelope 62 includes a standard bulb shape. This permission light 100 is used in any application/location that can be otherwise implemented by means of a standard incandescent light bulb. The envelope 62 can include or be used in conjunction with a diffuser. In some embodiments, the scattering particles are provided at the envelope 62 as an additional layer of material or directly incorporated within the envelope material 62 .

Any number of linear illumination configurations 21 may be included in the lamp 100 . 21 shows two linear illumination configuration in the embodiment of FIG. 34 in. FIG. 35 illustrates one embodiment in which three linear illumination configurations 21 are disposed within the lamp 100 . The exact number of linear illumination configurations 21 to be placed into the lamp 100 are selected to achieve the desired performance characteristics. An example of an additional LED bulb implemented using a linear illumination configuration is disclosed in the co-pending U.S. Patent Application Serial No. </RTI></RTI></RTI></RTI></RTI><RTIgt; The application is hereby incorporated by reference in its entirety.

Inline testing using any of the above methods can be employed to control and minimize variations in the final manufactured product. The method of U.S. Patent Application Serial No. 13/273,201, filed on Oct. 13, 2011, which is incorporated herein by reference in its entirety, is incorporated herein by reference to the entire entire entire entire entire entire entire entire entire entire entire entire content A method. The methods set forth in this co-pending application can be used in conjunction with the embodiments of the present invention and are hereby incorporated by reference in its entirety.

With a co-extrusion system, one possible method of performing in-line testing is to install the colorimeter or spectrometer when one of the color meter or spectrometer is actively squeezed. This measurement tool will typically be installed in-line after the cooling bath and dryer but before cutting. The color measurement provides instant feedback of the extrusion system that adjusts the layer thickness by varying the relative pressure of the two extrusion screws. The phosphor layer is made thicker or thinner to instantly tune the color of the product as it is squeezed. This allows for a single classification accuracy while enabling quality checks to be performed instantly during the extrusion process. Similar in-line testing can be used with printing and coating methods.

It is to be understood that the invention is not limited to the specific embodiments disclosed and may be modified within the scope of the invention. For example, although a lens is mentioned in the foregoing description, the phosphor can be deposited onto other optical components, such as, for example, a window (light passes through the window, but does not necessarily focus or guide) or guides, directs light. a waveguide. In addition, the optical components can be in many forms that will be readily apparent to those skilled in the art.

20‧‧‧Lighting diode lighting configuration / lighting configuration

22‧‧‧Light Emitting Diode/Light Emitting Diode Wafer

24‧‧‧Stainless steel case/reflector cup/shell

26‧‧‧Convex lens/lens/substantially spherical solid lens/optical component/elongated lens

28‧‧‧flat surface

30‧‧‧ Phosphor layer/phosphor/elongated phosphor layer/phosphor moiety

Claims (25)

A lamp comprising: a coextruded assembly comprising an elongate lens and a layer of photoluminescent material, wherein the elongate lens and the layer of photoluminescent material are coextruded together to form the coextruded component; the elongation a lens for shaping light emitted from the lamp, wherein the elongated lens comprises an elongated internal cavity; a layer of photoluminescent material on an inner wall of the elongated internal cavity; and a solid state light emitter array It is configured to emit light into the elongated internal cavity. A lamp as claimed in claim 1, wherein the lens corresponds to a curved outer wall. A lamp as claimed in claim 2, wherein the curved outer wall comprises a substantially semi-circular cross-sectional profile. A lamp as claimed in claim 1, wherein the inner wall of the elongated inner chamber corresponds to a generally curved inner wall. A lamp as claimed in claim 4, wherein the layer of photoluminescent material comprises a substantially conical profile. The lamp of claim 4, wherein the layer of photoluminescent material comprises a substantially semi-circular or dome-shaped cross-sectional profile. A lamp as claimed in claim 1, wherein the lens comprises a slot for assembling a circuit board having one of the linear solid state light emitter arrays. The lamp of claim 1 further comprising a diffusion material. A lamp as claimed in claim 8, wherein the diffusing material comprises an outer layer of material on the lens. The lamp of claim 8, wherein the diffusion material is attached to the lens or the photoluminescent material Within this layer. The lamp of claim 1 further comprising a reflector comprising a reflective surface for reflecting light emitted through the lens. A lamp as claimed in claim 11, wherein the reflector is coextruded with the elongate lens and the layer of photoluminescent material. The lamp of claim 11, wherein the layer of the reflector, the elongate lens, and a photoluminescent material are integrally formed as a multilayer optical component. A lamp as claimed in claim 1, further comprising an end cap attached to one of the ends of the lens. A lamp as claimed in claim 1, further comprising an optical medium within the cavity. The lamp of claim 15 wherein the optical medium is coextruded with the elongate lens and the layer of photoluminescent material. A lamp as claimed in claim 1, wherein the light emitted from the lamp is shaped by focusing. A method of making an optical component comprising coextruding an elongated solid body having a wavelength conversion layer and an optical component layer, the wavelength conversion layer being in contact with the optical component layer. The method of claim 18, wherein a plurality of separate extruders are employed to extrude the material of the wavelength conversion layer and the optical component layer. The method of claim 19, wherein the materials operated by the extruder comprise PC-polycarbonate, PMMA-poly(methyl methacrylate), PET-polyethylene terephthalate At least one of a fat and a thermoformed plastic. The method of claim 18, and further comprising coextruding a light diffusing portion. The method of claim 18, wherein the optical component layer is formed into a curved shape. The method of claim 18, wherein the optical component layer is a lens. The method of claim 18, further comprising performing an in-line program control to control deposition of material for the wavelength conversion layer. The method of claim 24, wherein the color measurement is performed for the in-line program control.