TW201420951A - LED bulb having a uniform light-distribution profile - Google Patents

LED bulb having a uniform light-distribution profile Download PDF

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Publication number
TW201420951A
TW201420951A TW102128312A TW102128312A TW201420951A TW 201420951 A TW201420951 A TW 201420951A TW 102128312 A TW102128312 A TW 102128312A TW 102128312 A TW102128312 A TW 102128312A TW 201420951 A TW201420951 A TW 201420951A
Authority
TW
Taiwan
Prior art keywords
light
casing
emitting diode
simulated
bulb
Prior art date
Application number
TW102128312A
Other languages
Chinese (zh)
Inventor
Matrika Bhattarai
Toquin Ronan Le
David Horn
Robert Edward Shroder
Robert Joseph Pagano
Original Assignee
Switch Bulb Co Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to US201261681123P priority Critical
Priority to US13/588,964 priority patent/US20140043821A1/en
Priority to US201361772473P priority
Priority to US13/842,855 priority patent/US20140043822A1/en
Priority to US13/892,186 priority patent/US20140334147A1/en
Application filed by Switch Bulb Co Inc filed Critical Switch Bulb Co Inc
Publication of TW201420951A publication Critical patent/TW201420951A/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00Globes; Bowls; Cover glasses
    • F21V3/02Globes; Bowls; Cover glasses characterised by the shape
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20Light sources comprising attachment means
    • F21K9/23Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20Light sources comprising attachment means
    • F21K9/23Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • F21K9/232Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21KNON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/60Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00Globes; Bowls; Cover glasses
    • F21V3/04Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21YINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2107/00Light sources with three-dimensionally disposed light-generating elements
    • F21Y2107/30Light sources with three-dimensionally disposed light-generating elements on the outer surface of cylindrical surfaces, e.g. rod-shaped supports having a circular or a polygonal cross section
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21YINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00Light-generating elements of semiconductor light sources
    • F21Y2115/10Light-emitting diodes [LED]

Abstract

An LED bulb includes a base, a shell, a plurality of LEDs, and a thermally conductive liquid. The shell is connected to the base. The plurality of LEDs is attached to the base and disposed within the shell. The thermally conductive liquid is held within the shell. The LED bulb is configured to produce a uniform light-distribution profile.

Description

Light-emitting diode bulb with uniform light distribution profile

The present application claims priority to U.S. Provisional Patent Application No. 61/681,123, filed on Aug. 8, 2012, and U.S. Provisional Patent Application No. 61/772,473, filed on Mar. The entire contents of the application are incorporated herein by reference. The present application also claims US Patent Application No. 13/588,964, filed on Aug. 17, 2012, and U.S. Patent Application Serial No. 13/842,855, filed on March 15, 2013, and on May 10, 2013 The priority of each application is incorporated herein by reference.

The present invention relates generally to liquid-cooled light-emitting diode (LED) bulbs and, more particularly, to techniques for producing light-emitting diode bulbs having a uniform light distribution profile.

Traditionally, light using fluorescent and incandescent light bulbs has been produced. Although this type of bulb has been used reliably, it has Some shortcomings. For example, incandescent light bulbs tend to be inefficient, using only 2 to 3% of their power to produce light, while 97-98% of the remaining power is lost in the form of heat. Fluorescent bulbs, although more efficient than incandescent bulbs, do not produce the same warm light as the incandescent bulbs. In addition, there are some health and environmental problems with regard to mercury contained in conventional fluorescent bulbs.

Therefore, there is a need for an alternative light source. One of the alternative light sources is a bulb that utilizes a light emitting diode (LED). The light emitting diode includes a semiconductor junction that emits light due to the flow of current through the junction. Compared to conventional incandescent light bulbs, light-emitting diode bulbs are capable of producing more light using the same amount of power. In addition, the operational life of a light-emitting diode bulb may be longer than the operational life of an incandescent light bulb, for example, the operating life of a light-emitting diode bulb is 10,000 to 100,000 hours compared to the working life of an incandescent light bulb. 1,000 to 2,000 hours.

For a light-emitting diode bulb, it may be advantageous to have a uniform light distribution profile over a major portion of the bulb surface. For example, the ENERGY STAR specification requires that there should be no more than a 20 percent change in the intensity of light emitted by the bulb from 0 to 135 degrees from the center of the bulb through the axis to the apex of the bulb. One of the challenges of using a light-emitting diode to make a light bulb is that, as provided by the ENERGY STAR specification, the light distribution of the light-emitting diode is not uniform in nature.

The apparatus and methods described herein can be used to fabricate light-emitting diode bulbs having a light distribution profile with improved uniformity of light distribution profile. In an embodiment, the LED bulb is provided with a compliance energy Uniformity of source star specifications.

In an exemplary embodiment, a light emitting diode bulb having a light distribution profile that meets the uniformity criteria is provided. The refractive index and contour shape of the simulated outer casing were obtained, and the refractive index of the simulated heat transfer liquid was obtained. An optical simulation model of the light-emitting diode bulb was established. The optical simulation model has a plurality of analog light-emitting diodes disposed in the analog housing, and an analog heat transfer liquid disposed between the plurality of analog light-emitting diodes and the interior of the analog housing. One or more of a height and an angle of the at least one analog light-emitting diode of the plurality of analog light-emitting diodes relative to the outer casing, a contour shape of the simulated outer casing having at least two radii, and a position of the diffuser light strip Will be calculated. The calculation is based on: an optical simulation model, a refractive index of the simulated outer casing, and a refractive index of the thermally conductive liquid. The calculation results in an estimated light distribution profile that varies 20 degrees or more relative to the average light intensity from 0 degrees to 135 degrees when measured from one axis extending from the center of the simulated housing to the apex of the simulated housing. less. The results of this calculation are stored in computer memory.

100‧‧‧(liquid filled) light-emitting diode (LED) bulb

101‧‧‧ Shell

103‧‧‧Lighting diode

107‧‧‧Support structure

110‧‧‧(light bulb) base

111‧‧‧Hot conductive liquid

115‧‧‧ terminal block

120‧‧‧ sac

122‧‧‧ diaphragm

130‧‧‧室

132‧‧‧ channel

1000‧‧‧ method

1002‧‧‧ operation

1004‧‧‧ operation

1006‧‧‧ operation

1008‧‧‧ operation

1100‧‧‧ method

1102‧‧‧ operation

1104‧‧‧ operation

1106‧‧‧ operation

1108‧‧‧ operation

1200‧‧‧ method

1202‧‧‧ operation

1204‧‧‧ operation

1206‧‧‧ operation

1208‧‧‧ operation

1300‧‧‧ method

1302‧‧‧ operation

1304‧‧‧ operation

1306‧‧‧ operation

1308‧‧‧ operation

Figure 1 depicts a light emitting diode bulb.

2A and 2B depict a light emitting diode bulb having a liquid expansion compensator.

3A to 3D depict exemplary aspects of a light-emitting diode bulb law.

4A to 4L depict analysis results of a light-emitting diode bulb having various types of light-emitting diode mounting angles and heights.

5A to 5C depict the divergence intensity of a light-emitting diode bulb having various types of light-emitting diode mounting angles and heights.

6A to 6C depict the divergence uniformity of a light-emitting diode bulb having various types of light-emitting diode mounting angles and heights.

7A to 7L depict the dimensions of a light-emitting diode bulb having various types of light-emitting diode mounting angles and heights.

8A to 8B depict a light-emitting diode bulb having various outer casing contour shapes.

Figure 9 depicts the divergence uniformity of a light-emitting diode bulb having various contour shapes of the outer casing.

Figure 10 depicts a light emitting diode bulb with a diffuser strip of light.

Figure 11 depicts the divergence uniformity of a light-emitting diode bulb with a diffuser strip.

Figure 12 depicts the divergence uniformity of an exemplary analog light-emitting diode bulb and an actual light-emitting diode bulb.

Figure 13 depicts an exemplary bidirectional reflectance distribution function for a simulated support structure of a simulated light-emitting diode bulb and a simulated pedestal.

The following description is presented to make any of the techniques well known. Various embodiments can be made and used by those skilled in the art. Descriptions of specific devices, techniques, and applications are provided merely as examples. Various modifications to the examples described herein will be apparent to those skilled in the art, and the general principles defined herein may be applied to other examples without departing from the spirit and scope of the various embodiments. And application. Therefore, the various embodiments are not intended to be limited to the examples described and illustrated herein, but should be accorded to the scope of the application.

Various embodiments relating to a light-emitting diode bulb are described below. As used herein, "light emitting diode bulb" refers to any light generating device (eg, a light) in which at least one light emitting diode is included to generate light. Thus, as used herein, a "light emitting diode bulb" does not include a light generating device that uses a filament to generate light, such as a conventional incandescent light bulb. It will be appreciated that the light-emitting diode bulbs can have a variety of shapes other than the A-bulb-like shape of a conventional incandescent light bulb. For example, the bulb may have a tubular, spherical, or similar shape. The light-emitting diode bulb of the present invention may also include any type of connector, such as a screw-in base, a double-pronged joint, a standard two or three-prong wall socket plug, a socket, a spiral light bulb base, and a single-pin base. , a multi-pin base, a recessed base, a flanged base, a grooved base, a side base, or the like.

The term "liquid" as used herein refers to a flowable substance. Further, the substance used as the heat transfer liquid is a liquid or a substance which is at least in a liquid state in the working temperature range of the bulb. An exemplary temperature range includes temperatures between -40 degrees C and +50 degrees C. this In addition, "passive convection flow" as used herein refers to a liquid circulation that does not require the help of a fan or other mechanical means to drive the flow of the thermally conductive liquid.

1. Liquid filled LED bulb

FIG. 1 depicts an exemplary liquid filled LED bulb 100. The LED bulb 100 includes a base 110 and a housing 101 surrounding various components of the LED bulb 100. The outer casing 101 is coupled to the base 110 to form a closed volume. A column of light emitting diodes 103 is mounted to the support structure 107 and disposed within the enclosed volume. The enclosed volume is filled with the heat transfer liquid 111.

For the sake of convenience, all of the examples provided by the present invention describe and display a light-emitting diode bulb 100 of a standard A-type bulb. However, as described above, it should be understood that the present invention may be applied to a light-emitting diode bulb having any shape, such as a tubular bulb, a bulb, or the like.

The outer casing 101 may be made of any transparent or translucent material such as plastic, glass, polycarbonate, and the like. The outer casing 101 may be transparent or frosted to disperse light generated by the light emitting diodes. The outer casing 101 has a geometric center and a vertex at the top of the light-emitting diode bulb 100, as shown in FIG.

As noted above, bulbs generally conform to standard form factors that allow for bulb interchangeability between different lighting fixtures and appliances. Thus, in the present exemplary embodiment, the LED bulb 100 includes a terminal block 115 for connecting the bulb to a lighting fixture. In an example In this case, the terminal block 115 may be a conventional bulb base with threads 117 for insertion into a conventional lamp socket. However, as noted above, it should be understood that the terminal block 115 may be any form of connector for mounting the light emitting diode bulb 100 or for coupling to a power source. For example, the terminal block may be screwed into the base, a double-pronged joint, a standard two or three-pronged wall socket plug, a socket, a spiral light bulb base, a single-pin base, a multi-pin base, a female base, and a convex The rim base, the groove base, the side pedestal, and the like provide for mounting.

In some embodiments, the LED bulb 100 can use 6 watts or more of power to generate light equivalent to a 40 watt incandescent bulb. In some embodiments, the LED light bulb 100 can use 18 watts or more of power to generate light that is equivalent to or greater than a 75 watt incandescent bulb. Depending on the efficiency of the light-emitting diode bulb 100, thermal energy between 4 watts and 16 watts may be generated when the light-emitting diode bulb 100 is illuminated.

The light-emitting diode bulb 100 includes several components for dissipating heat generated by the light-emitting diode 103. For example, as shown in FIG. 1, the light-emitting diode bulb 100 includes one or more support structures 107 for holding the light-emitting diodes 103. The support structure 107 may be made of any thermally conductive material such as aluminum, copper, brass, magnesium, zinc, and the like. In some embodiments, the support structure is made of a composite laminate. Since the support structure 107 is made of a heat conductive material, heat generated from the light emitting diode 103 is conductively transferred to the support structure 107 and transmitted to other members of the light emitting diode bulb 100 and the surrounding environment. Therefore, the support structure 107 can function as a heat sink or a heat dispersion device of the light emitting diode 103.

The support structure 107 is connected to the bulb base 110, allowing heat generated from the LEDs 103 to be conducted to other portions of the LED bulb 100. The support structure 107 and the bulb base 110 may be formed in one piece or in multiple pieces. The bulb base 110 can likewise be made of a thermally conductive material and is coupled to the support structure 107 such that heat generated from the LEDs 103 is conducted into the bulb base 110 in an efficient manner. The bulb base 110 is also connected to the outer casing 101. The bulb base 110 can also be thermally conducted to the outer casing 101.

The bulb base 110 also includes one or more components that provide structural features for mounting the bulb housing 101 and the support structure 107. The components of the bulb base 110 include, for example, sealing gaskets, flanges, rings, adapters, and the like. The bulb base 110 can also include a terminal block 115 for connecting the light bulb to a power source or lighting fixture. The bulb base 110 can also include one or more die cast parts.

The light-emitting diode bulb 100 is filled with the heat transfer liquid 111 for transferring heat generated from the light-emitting diode 103 to the outer casing 101. The heat transfer liquid 111 fills the enclosed volume defined between the outer casing 101 and the bulb base 110, allowing the heat transfer liquid 111 to conduct heat to the outer casing 101 and the bulb base 110. In some embodiments, the heat transfer liquid 111 is in direct contact with the light emitting diode 103.

The heat transfer liquid 111 may be any heat transfer liquid, mineral oil, polyoxygenated oil, glycols (PAGs), carbonized fluorine, or other flowable materials. A liquid having a medium selected to be non-corrosive is desirable. Choosing such a liquid can reduce the possibility that the liquid will cause an electrical short circuit Sex, and reduce damage to such components of the LED bulb 100.

The light-emitting diode bulb 100 includes a mechanism that allows thermal expansion of the heat transfer liquid 111 contained in the light-emitting diode bulb 100. In the exemplary embodiment, the mechanism is a sac 120. In FIG. 2A, the bladder 120 is disposed in a chamber 130 of the bulb base 110. The chamber 130 is in fluid communication with a closed volume established between the outer casing 101 and the base 110. As shown in FIG. 2A, the passage 132 connects the enclosed volume and the chamber 130, allowing the heat transfer liquid 111 to enter the chamber 130. The outer surface of the sac 120 is in contact with the heat transfer liquid 111. The volume of the chamber that is not occupied by the sac 120 is typically filled with the heat transfer liquid 111. The bladder 120 can be compressed and/or expanded to compensate for the expansion of the thermally conductive liquid 111.

FIG. 2B depicts an alternative configuration using diaphragm 122 to compensate for thermal expansion of the thermally conductive liquid. In this embodiment, a surface of the diaphragm 122 is fluidly coupled to the thermally conductive liquid. The other surface is typically exposed to ambient pressure (eg, communicating with ambient air outside the bulb). The diaphragm 122 is deformable and/or movable to compensate for the expansion of the heat transfer liquid 111.

The use of liquid filled bulbs offers several distinct advantages over conventional gas filled bulbs. As discussed above, a bulb filled with a thermally conductive liquid provides better heat dissipation from the LEDs than an inflated bulb. In addition, since the heat transfer liquid system is disposed between the light emitting diode and the outer casing, the heat conductive liquid can serve as a lens for guiding the light emitted by the light emitting diodes.

As discussed above, it is expected to be manufactured with A light-emitting diode bulb that meets the ENERGY STAR requirements for a uniform light distribution profile. In particular, as provided in Section 7A of the ENERGY STAR Program Requirements for Monolithic Light Emitting Diodes, it may be desirable to fabricate a light-emitting diode bulb having a light distribution profile that extends from the center of the housing When measured on one axis to the apex of the outer casing, the light distribution profile does not vary by more than 20 percent from 0 degrees to 135 degrees. It can also be expected to manufacture LED light bulbs that exceed the ENERGY STAR uniformity requirements. For example, it may be desirable to fabricate a light-emitting diode bulb having a light distribution profile that does not vary by more than 18, 15, 14, or 11 percent from 0 degrees to 135 degrees. However, as mentioned previously, the light-emitting diode bulb itself may not produce a uniform light distribution profile that meets these criteria.

The technique discussed below utilizes the optical properties of a liquid-filled LED bulb to produce a light-emitting diode bulb having a uniform light distribution. Specifically, the vertical position and angle of the light-emitting diodes in the outer casing, the shape of the outer casing, and the diffuser light strip on the outer casing may be used alone or in combination to manufacture an energy star specification. The light-emitting diode bulb of the projected light distribution profile.

In the examples provided below, in order to model, the light-emitting diodes are assumed to have a Lambertian divergence profile having a peak light intensity at an angle close to the face perpendicular to the light-emitting diode. In general, less light diverges from the light-emitting diode as the divergence angle from the face of the light-emitting diode increases. The light distribution profile of a typical light-emitting diode (without the aid of additional optical components) may not meet the uniformity criteria provided by the ENERGY STAR specification.

A liquid filled housing can be used to increase the uniformity of light emitted from the light emitting diode. In the examples provided below, the outer shell having a refractive index of about 1.5 is filled with a heat transfer liquid having a refractive index of about 1.4. The outer casing and the heat transfer liquid together act as a lens for transferring light to a portion of the light emitting diode that is toward the light emitting diode bulb that may be weaker.

The refractive index of the outer casing and the heat transfer liquid, the angle and position of the light emitting diode relative to the outer casing, the contour shape of the outer casing, and the position of the diffuser light band all affect how the light emitted from the light emitting diode is illuminated by the light The polar bulb is transferred. As discussed in detail below, one or more of these parameters can be optimized to produce a light emitting diode bulb having a projected light distribution profile that meets the uniformity criteria.

2. Calculate the angle and height of the LED

As discussed above, it may be desirable to fabricate a light-emitting diode bulb having a light distribution profile that meets the ENERGY STAR uniformity requirements. In particular, it may be desirable to fabricate a light-emitting diode bulb having a light distribution profile that is compared to at 0 degrees when measured from an axis extending from the center of the outer casing to the apex of the outer casing. The average light intensity to 135 degrees does not change by more than 20%.

Using the liquid filled bulb as described above in Figure 1, the light emitting diode, the heat conducting liquid, and the outer casing form an optical system that can be configured to produce the desired light distribution. In the example described below, the vertical position and angle of the light-emitting diode relative to the outer casing are calculated to produce A light-emitting diode bulb having a light distribution profile that meets specified uniformity criteria.

3A depicts an exemplary method 1100 of providing a light emitting diode (LED) bulb having a light distribution profile that meets uniformity criteria by calculating the angle and height of the light emitting diode. Method 1100 can be used to calculate the optical configuration of a light-emitting diode bulb having a projected light distribution profile that meets the ENERGY STAR uniformity requirements.

In operation 1102, the optical properties of the outer casing and the thermally conductive liquid are taken. The optical properties may include, for example, the refractive index and light transmission coefficient of the outer casing and the thermally conductive liquid. In addition, the refractive index of the optical coating film on the outer casing or other optical member may be obtained as well.

In operation 1104, an optical simulation model is established. The optical simulation model simulates the optical and geometric configuration of a light-emitting diode bulb with respect to optical analysis of a light-emitting diode bulb. In this example, the optical simulation model simulates the geometry and position of the light-emitting diode bulb component with an optical analysis of the far-field intensity of light emitted from one or more light-emitting diodes. The optical simulation model is typically built using a computer system having a processor and computer readable memory configured to execute the optical simulation software. Available optical modeling tools are available, including, for example, APEX optical modeling software for use with SolidWorks solid component models manufactured by Breault Research Organization, or LightTools optical design and analysis software manufactured by Synopsys To establish the optical simulation model.

In an example, the optical simulation model includes a set in mode One or more analog light-emitting diodes (of a plurality of light-emitting diodes) in the outer casing, and a simulated heat transfer fluid system is disposed between the one or more analog light-emitting diodes and the interior of the simulated casing. The optical simulation model can also include a simulated pedestal, a simulated support structure, and other analog components of the light emitting diode bulb. 4A depicts a cross-sectional view of an optical simulation model including two analog light emitting diodes, a simulated heat transfer liquid, a simulated housing, a simulated support structure, and a simulated pedestal. The geometry of the simulated components can be built using a commercially available modeling tool, such as a solid modeling tool of SolidWorks. The geometry of the components can be imported into the optical simulation model by, for example, an APEX optical modeling tool.

In operation 1106, the angle and height of the light emitting diode are calculated. In this example, the angles and heights of the light emitting diodes are calculated based on the optical simulation model established in operation 1104 and the optical characteristics obtained in operation 1102. In particular, in this example, the optical simulation model is used to perform at least one optical analysis to obtain a far field intensity distribution in a designated region of the analog light emitting diode bulb. The optical analysis can include a ray tracing optical analysis that calculates the intensity and angle of the plurality of simulated light rays emitted by the one or more analog light emitting diodes. Light scattering, reflection and absorption can also be calculated as part of this optical analysis.

For operation 1106, various measurements can be performed using the individual LED angles and the LED height to achieve a variety of far field intensity distributions. Figures 4A through 4L depict exemplary optical analysis results for multiple light-emitting diode angles and light-emitting diode heights, which will be followed in more detail. discuss. In the results depicted in Figures 4A through 4L, other parameters, such as the outline and thickness of the outer casing, are constant. In order to perform a variety of analyses, various parameters of the LED bulb, such as the position of the LED, can be modified using optical modeling tools (eg, APEX), or from other modeling software tools (eg, SolidWorks entities) The modeling tool) is re-imported into the optical modeling tool. The results of this various optical analysis can be compared to select the angle and height of the light-emitting diode, which results in a light distribution profile that meets the uniformity criteria. As mentioned earlier, this uniformity criterion may be based on the ENERGY STAR specification of the uniformity of the light distribution profile.

In the examples provided below in FIGS. 4A to 4L, various analyses of the angle of the light emitting diode in units of 2 degrees and the height of the light emitting diode in units of 2 mm can be performed. The range of average light intensities at the profile angle can be simulated and the mean difference can be calculated. The angle and height of the light-emitting diodes can be calculated by optimizing the angle of the light-emitting diode and the deviation of the height of the light-emitting diode. In an example, the mean deviation is optimized by varying the angle of the light emitting diode. The mean deviation can then be optimized by varying the height of the light-emitting diode. The optimization of the angle of the light-emitting diode can be performed again for the optimum height of the light-emitting diode. Other techniques for optimizing the light distribution profile for the angle and height of the light-emitting diodes can be performed as well.

In another implementation, a plurality of candidate configurations can be selected to have a deviation from the average light intensity that does not exceed a threshold (eg, 20 percent) from 0 degrees to 135 degrees. Any one of the selected configurations can be used to fabricate one of the light distribution profiles having a uniformity criterion light bulb. In some cases, the candidate with the most uniform light distribution profile is selected as the optimal configuration.

In operation 1108, the results are stored in computer memory. In some cases, the heights and angles calculated in operation 1106 are stored in a computer readable memory including a dynamic random access memory (RAM), a hard disk storage medium, an optical storage medium, or the like. In some cases, the results of at least one optical analysis performed in operation 1106 are stored in computer readable memory. The stored results can be used to construct a light emitting diode bulb having one or more light emitting diodes disposed within the housing at an angle and height calculated in operation 1106. In some embodiments, the stored results can be used to fabricate a light-emitting diode bulb having an estimated light distribution profile that is predicted from an axis extending from the center of the outer casing to the apex of the outer casing. The light distribution profile does not deviate from the average by more than 20% from 0 to 135 degrees.

As previously mentioned, Figures 4A through 4L depict the results of optical analysis of the analog light-emitting diode bulb for various angular and vertical positions (i.e., height) of the light-emitting diode. The simulations of Figures 4A through 4L are performed for simulating a light-emitting diode bulb with one of the analog light-emitting diodes having a Lambertian divergence profile and a standardized lumen light output. The analog light-emitting diode bulb shown in Figures 4A through 4L includes a simulated housing having a uniform radius of 60 mm and a simulated base having a width of about 60 mm at the intersection of the base and the housing.

This analysis considers the optical properties of the various components of the light-emitting diode bulb. For the analysis described in Figures 4A to 4L, heat conduction The refractive index of the liquid is assumed to be 1.41 for the simulation system, and the refractive index of the outer shell is assumed to be 1.52 for the simulation system. For all the simulations provided herein, the simulations were normalized to 1 lumen per simulated light-emitting diode. The optical properties of the pedestal and support structure, including surface luminosity for simulated optical scattering, are also taken into account. Figure 13 depicts an exemplary bidirectional reflectance distribution function (BRDF) applied to a simulated support structure and a simulated pedestal.

The optical analysis described in Figures 4A through 4L simulates the far field light distribution of various configurations of a simulated light emitting diode bulb. Specifically, the far-field light distribution measured by candlelight, such as measuring an axis extending from the center of the outer casing to the apex of the outer casing, is simulated and reported in units of 5 degrees. The far field luminous flux measured in lumens is also simulated and reported in units of 10 degrees. The difference in percentage of light intensity compared to the average light intensity is also calculated and reported in units of 5 degrees. The selected dimensions of the various configurations of the light-emitting diode bulb are shown in Figures 7A through 7L and correspond to the optical analysis shown in Figures 4A through 4L.

4A depicts an optical analysis of a light-emitting diode bulb having a nominal light-emitting diode height (26.37 mm from the bottom edge of the housing, or 3.87 mm from the center of the housing), and 5 degrees. The LED is mounted at an angle. As shown in Figure 4A, a nominal height between 0 and 135 degrees results in a maximum percentage deviation from the average of +15% and -25%. 4B depicts an optical analysis of a light-emitting diode bulb having a height of about +3 mm from the nominal (29.36 mm from the bottom edge of the housing, or 6.86 mm from the center of the housing), and 5 Degree of hair The angle of the light diode is set to cause a maximum deviation of +20% and -25% from the average. 4C depicts an optical analysis of a light-emitting diode bulb having a height of approximately +5 mm from the nominal (31.35 mm from the bottom edge of the housing, or 8.51 mm from the center of the housing), and 5 The degree of illumination of the LED is set to an angle that causes a maximum deviation of +22% and -31% from the average.

4D to 4F depict a configuration having a light-emitting diode mounting angle of 7 degrees. Figure 4D depicts a light-emitting diode bulb having a nominal light-emitting diode height (26.37 mm from the bottom edge of the housing, or 3.87 mm from the center of the housing), resulting in +14% at 0 to 135 degrees and - 18% of the maximum deviation from the mean. Figure 4E depicts a light-emitting diode bulb having a height of about +3 mm from the nominal (29.37 mm from the bottom edge of the housing, or 6.85 mm from the center of the housing), resulting in +17% and -21% The maximum deviation of the mean. Figure 4E depicts a light-emitting diode bulb having a height of about +5 mm from the nominal (31.38 mm from the bottom edge of the housing, or 8.83 mm from the center of the housing), resulting in a +18% and -24% The maximum deviation of the mean.

4G to 41 depict a configuration having a light-emitting diode mounting angle of 9 degrees. Figure 4G depicts a light-emitting diode bulb having a nominal light-emitting diode height (26.46 mm from the bottom edge of the housing, or 3.96 mm from the center of the housing), resulting in +12% at 0 to 135 degrees and - 25% of the maximum deviation from the mean. Figure 4H depicts a light-emitting diode bulb having a height of about +3 mm from the nominal (29.33 mm from the bottom edge of the housing, or 6.83 mm from the center of the housing), resulting in +14% and -15% level The maximum deviation of the mean. Figure 41 depicts a light-emitting diode bulb having a height of about +5 mm from the nominal (31.31 mm from the bottom edge of the housing, or 8.81 mm from the center of the housing), resulting in +14% and -18% The maximum deviation of the mean.

4J to 4L describe the configuration of the light-emitting diode mounting angle of 11 degrees. Figure 4J depicts a light-emitting diode bulb having a nominal light-emitting diode height (26.37 mm from the bottom edge of the housing, or 3.87 mm from the center of the housing), resulting in +10% at 0 to 135 degrees and - 31% of the maximum deviation from the mean. Figure 4K depicts a light-emitting diode bulb having a height of about +3 mm from the nominal (29.32 mm from the bottom edge of the housing, or 6.82 mm from the center of the housing), resulting in +12% and -21% The maximum deviation of the mean. Figure 4L depicts a light-emitting diode bulb having a height of about +5 mm from the nominal (31.28 mm from the bottom edge of the housing, or 8.78 mm from the center of the housing), resulting in +13% and -14% The maximum deviation of the mean.

As discussed above in method 1100, the analysis performed in Figures 4A through 4L can be used to calculate a light-emitting diode that causes a light-emitting diode bulb to produce a light distribution profile that meets the ENERGY STAR uniformity criteria. Angle and height. In this example, four of the 12 configurations described in Figures 4A through 4L meet ENERGY STAR's criteria for light distribution profile uniformity: Figure 4D depicts a 7 degree LED dipole angle and nominal a light-emitting diode bulb having a height of a light-emitting diode; a light-emitting diode bulb having a 9-degree light-emitting diode angle and a +3 mm light-emitting diode height as depicted in FIG. 4H; FIG. 4I having a 9-degree light-emitting diode Body angle and A light-emitting diode bulb having a height of +5 mm LED; and a light-emitting diode bulb having an 11-degree light-emitting diode angle and a +5 mm light-emitting diode height as described in FIG. 4L. Thus, according to the analysis performed in Figures 4A through 4L, a light-emitting diode bulb having 7, 9, and 11 degree light-emitting diode angles with their respective nominal, +3 mm, and +5 mm light-emitting diode positions It can be configured to produce a light distribution profile that meets the ENERGY STAR uniformity criteria. More specifically, there are a plurality of light-emitting diodes having a position of between 3.5 mm and 10 mm from the center of the outer casing and positioned at an angle of between 4 and 12 degrees to the central axis of the outer casing. A polar bulb can also be configured to produce a light distribution profile that meets the ENERGY STAR uniformity criteria.

Figures 5A through 5C and Figures 6A through 6C depict other visualizations of the results of the analysis performed in Figures 4A through 4L. Figures 5A through 5C depict simulations of light intensity versus angle for the analysis performed for the light-emitting diode bulbs shown in Figures 4A through 4L. Figures 6A through 6C depict the deviation from the mean versus angle for the analysis performed for the light-emitting diode bulbs shown in Figures 4A through 4L.

The analysis of the analysis as shown in Figures 5A through 5C and Figures 6A through 6C has a trade-off between the angle of the light-emitting diode and the height of the light-emitting diode. For the housing configuration molded in Figures 4A through 4L, the increase in the angle of the LED causes more light to the position near the apex of the housing and less light to a position exceeding 100 degrees from the apex. . In the example provided above, an 11 degree illuminator angle results in a light distribution profile with the most uniformity between 0 and 135 degrees from the apex.

For the housing configuration molded in Figures 4A through 4L, the increase in the height of the LED causes more light to be transferred beyond the 100 degree position from the apex, and less light is transferred to the apex. A position between 0 and 25 degrees. In the example provided above, the height of the light-emitting diode nominally about +5 mm (and the angle of the light-emitting diode at 11 degrees) results in the most uniform between 0 and 135 degrees from the apex. Sexual light distribution profile.

3. Calculate the shape of a casing of a liquid-filled LED bulb

Using a liquid filled bulb as described above in Figure 1, the light emitting diode, the heat conducting liquid, and the outer casing form an optical system that can be configured to produce the desired light distribution profile. In the example described below, the shape of the outer casing is calculated to produce a light-emitting diode bulb having a light distribution profile that meets the uniformity criteria.

As discussed above, a light-emitting diode having a Lambertian profile tends to produce most of the light perpendicular to the face of the light-emitting diode and less light as the angle is more vertically offset. One of the benefits of using a liquid filled bulb is that the thermally conductive liquid and the outer shell together form a lens that can be shaped to redirect light emitted by the light emitting diode from the central portion of the outer casing to other portions of the outer casing. In the examples provided below, an outer casing comprising a contoured shape having a plurality of radii can be configured to produce a light emitting diode bulb having a light distribution profile that meets the uniformity criteria.

FIG. 3B depicts an exemplary method 1200 for The shape of the outer casing is calculated to provide a light-emitting diode bulb having a light distribution profile that meets the uniformity criteria. Method 1200 can be used to calculate an optical configuration of a light emitting diode bulb having a light distribution profile that meets the ENERGY STAR uniformity requirements.

In operation 1202, the optical properties of the outer casing and the thermally conductive liquid are taken. Such optical properties may include, for example, the refractive index and light transmission coefficient of the outer casing and the thermally conductive liquid. In addition, the refractive index of the optical coating film on the outer casing or other optical member may be obtained as well.

In operation 1204, an optical simulation model is established. The optical simulation model simulates the optical and geometric configuration of a light-emitting diode bulb with respect to optical analysis of a light-emitting diode bulb. In this example, the optical simulation model simulates the geometry and position of the light-emitting diode bulb component with an optical analysis of the far-field intensity of light emitted from one or more light-emitting diodes. An example of establishing an optical simulation model is provided at operation 1104 of Figure 3A above.

In operation 1206, the contour shape of the simulated housing is calculated. In this example, the contour shape is calculated based on the optical simulation model established in operation 1204 and the optical characteristics obtained in operation 1202. In particular, in this example, the optical simulation model is used to perform at least one optical analysis to obtain a far field intensity distribution in a designated region of the analog light emitting diode bulb. The optical analysis can include a ray tracing optical analysis that calculates the angle and intensity of the plurality of simulated light rays emitted by the one or more analog light emitting diodes. Light scattering, reflection and absorption can also be counted as part of this optical analysis. Count.

In the examples provided below, the contour shape is defined using two or more radial limits. Specifically, for the position of two or more of the contour shapes, a distance from the contour shape to the center of the outer casing is defined. As shown in Figures 8A through 8B, the outer casing profile having multiple distances from the edge of the outer casing to the center of the outer casing will likewise have multiple radii. In this embodiment, a first radial limit of the first portion of the contour shape is achieved, the first portion being located between 0 and 40 degrees measured from the apex of the outer casing. A second radial limit of the second portion of the contour shape between 40 degrees and 90 degrees measured from the vertex is taken. A third radial limit of the third portion of the contour shape located between 90 degrees and 130 degrees measured from the vertex is calculated. The contour shape is calculated based on the first, second, and third radial limits.

In the present embodiment, the spline function is used to calculate the shape of the outer casing that satisfies two or more radial limits. In other embodiments, the two or more radial limits may be specified by specifying two or more radius values, diameter values, housing width values, or the like. Using parametric modeling tools such as SolidWorks, the two or more radial limits can be specified using various geometric limits and blending using spline or curve fitting functions. Other geometric limits, such as the overlapping and tangential sealing of the sealing flange on the outer casing, can also be used to meet other functional requirements of the outer casing.

With regard to operation 1206, various outer shell contour shapes can be used to perform a variety of analyses to achieve a variety of far field intensity distributions. Figures 8A through 8B depict exemplary optical analysis of various optical analyses of simulated housings having different radii If there is a more detailed discussion later. To perform a variety of analyses, the geometry of the enclosure and other parameters can be modified using optical modeling tools (eg, APEX) or re-imported from other modeling software tools (eg, SolidWorks' solid modeling tools). Mold tool.

The results of various optical analyses can be compared to calculate a bulb shape that results in a light distribution profile that meets the uniformity criteria. As mentioned earlier, this uniformity criterion may be based on the ENERGY STAR specification of the uniformity of the light distribution profile. In the examples provided below with respect to Figures 8A through 8B, various analyses can be performed to simulate an outer casing having a different contour shape. In this example, the apex of the outer casing and the contour shape of the pedestal are flattened in different amounts to achieve the contour shape of the various simulated outer casings. The average light intensity of each contour shape can be simulated, and the deviation from the average value can be calculated. The contour shape of the outer casing can be calculated by, for example, optimizing the deviation of the zero radial limit of the contour shape from the mean value. In the example provided in Figures 8A through 8B, flattening the contour shape near the apex of the outer casing (reducing the distance from the edge of the outer casing to the center of the outer casing) increases the light intensity in the region near the apex of the light-emitting diode bulb. Likewise, flattening the contoured shape of the base adjacent the outer casing increases the light intensity near the base of the outer casing.

In another implementation, a plurality of candidate configurations can be selected to have a deviation from the average light intensity of less than a threshold (eg, 20 percent) from 0 degrees to 135 degrees. Any one of the selected configurations can be used to fabricate a light-emitting diode lamp having a light distribution profile that meets the uniformity criteria bubble. In some cases, the candidate with the most uniform light distribution profile is selected as the optimal configuration.

In operation 1208, the results are stored in computer memory. In some cases, the contour shape calculated in operation 1206 is stored in a computer readable memory including a dynamic random access memory (RAM), a hard disk storage medium, an optical storage medium, or the like. In some cases, the result of at least one optical analysis performed in operation 1206, including one or more radial limits, is stored in a computer readable memory. The stored results can be used to construct a light emitting diode bulb that includes a housing having the contour shape calculated in operation 1206. In some embodiments, the stored results can be used to fabricate a light-emitting diode bulb having an estimated light distribution profile that is predicted from an axis extending from the center of the outer casing to the apex of the outer casing. The light distribution profile does not deviate from the average by more than 20% from 0 to 135 degrees.

8A-8B depict an exemplary simulated housing having a contoured shape that can be used to fabricate a light emitting diode bulb having a light distribution profile that meets the uniformity criteria. For the example provided below, the light-emitting diode system is positioned at an angle of 9 degrees and a position of +3 mm with respect to the nominal.

For the purpose of analysis, the heat transfer liquid had a refractive index of 1.4015, the outer shell had a refractive index of 1.52, and the outer shell had a thickness of 3 mm. For all of the simulations provided herein, the simulations were normalized to 1 lumen per simulated light-emitting diode. The optical properties of the pedestal and support structure, including surface luminosity for simulated optical scattering, are also taken into account. Figure 13 describes an exemplary bidirectional reflectance distribution function (BRDF) applied to a simulated support structure and a simulated pedestal.

Figure 8A depicts a housing outline having a distance of 27.9 mm from the center of the housing to the contour of the housing for a first portion of the housing located approximately 30 degrees from the apex of the housing, and about 100 degrees from the apex of the housing. The third part of the outer casing has a contour of 26 mm.

Figure 8B depicts a housing outline having a distance of 26.8 mm from the center of the housing to the contour of the housing for a first portion of the housing located approximately 30 degrees from the apex of the housing, and about 100 degrees from the apex of the housing In the third part of the outer casing, the outer casing profile has a distance of 26.3 mm.

Figure 9 depicts the results of an analysis of a simulated housing with five different contour shapes. In particular, Figure 9 depicts an intensity distribution and intensity uniformity at angles from 0 to 135 degrees from the apex of the outer casing.

Figure 9 depicts the result of a first contour shape ("preset") having a uniform radius of 30 mm. The second contour shape has a distance of 26 mm from the outline of the outer casing to the center of the outer casing at a distance of 100 degrees from the apex, a distance of 27 mm from 45 degrees from the apex, and 27.9 mm at 30 degrees from the apex. Distance ("190_26_135_27_120_27.9"). The third contour shape has a distance of 26.5 mm from the outline of the outer casing to the center of the outer casing from the apex of 100 degrees, a distance of 27 mm from 55 degrees from the apex, and 27.5 mm at 30 degrees from the apex. Distance ("190_26.5_145_27_120_27.5"). The fourth contour shape is at the top The point of 100 degrees has a distance of 26.3 mm from the outline of the outer casing to the center of the outer casing, and a distance of 26.8 mm ("190_26.3_145f_120_26.8") from 30 degrees from the apex. The fifth contour shape has a distance of 26.5 mm from the outer casing contour to the center of the outer casing from the apex of 95 degrees, and a distance of 26.8 mm ("185_26.3_145f_120_26.8") from 30 degrees from the apex.

As shown in Figure 9, the first, fourth, and fifth contour shapes have a projected light distribution profile that meets the ENERGY STAR uniformity criteria. The fourth contour shape has the most uniform projected light distribution profile among the five contour shapes. The first, third, fourth or fifth contour shapes can be used to fabricate a light-emitting diode bulb having a light distribution profile that meets the ENERGY STAR uniformity criteria.

4. Diffuse body light band

Using the liquid filled bulb as described above in Figure 1, the light emitting diode, the heat conducting liquid, and the outer casing form an optical system that can be configured to produce the desired light distribution profile. In the example described below, the position of a diffuser strip is calculated to produce a light-emitting diode bulb having a light distribution profile that meets the uniformity criteria.

As discussed above, a light emitting diode having a Lambertian profile tends to produce most of the light in a plane perpendicular to the light emitting diode and less light as the angle of the distance surface increases. A method of transferring light to the upper and lower portions of a light-emitting diode bulb by calculating the angle of the light-emitting diode, the height of the light-emitting diode, and the shape of the contour bulb has been previously discussed in Figures 3A and 3B above. In the example provided below, A diffuser light strip is used to disperse light near the middle of the light-emitting diode bulb to produce a light-emitting diode bulb having a desired light distribution profile. Specifically, the position of the diffuser light strip relative to the plurality of light emitting diodes is calculated to produce a light emitting diode bulb having a light distribution profile that meets the ENERGY STAR uniformity criteria.

In some embodiments, the diffuser light strip may not improve the uniformity of the light distribution profile, but may meet other design requirements. For example, a diffuser volume band can be used to reduce the occurrence of point sources that produce self-luminous diodes. In other embodiments, a diffuser light strip can be used to shield portions of the light emitting diode bulb that are viewed from the outside. For example, it may be desirable to be unable to see the light emitting diode from the outside of the bulb. Diffuse light strips can also be used to create specialized lighting effects.

In the example provided below, the diffuser light strip is an area of the outer casing that is treated to disperse light generated by the plurality of light emitting diodes to a larger area than other areas of the outer casing in a designated area of the outer casing. Angle. For the purposes of this discussion, a diffuser volume band does not occupy an area that substantially covers the entire optical surface of the housing. In one embodiment, the diffuser strip can be created by sandblasting a glass envelope using various grit sizes. For example, a grit size of 180, 220, 320, 400 grit can be used. In some cases, the interior or exterior of the outer casing may be coated with one of the materials that create a diffuse increase in the area. For example, the outer casing may be coated with a chemical coating or aqueous coating that produces an increase in diffusion. In another embodiment, a chemical treatment can be used to etch the outer casing to create an increase in diffusion in a given area.

3C depicts an exemplary method 1300 for providing a light emitting diode bulb having a light distribution profile that meets the uniformity criteria by calculating the position of a diffuser light strip. Method 1300 can be used to calculate an optical configuration of a light emitting diode bulb having a light distribution profile that meets the energy star uniformity requirements.

In operation 1302, the optical properties of the outer casing and the thermally conductive liquid are taken. Such optical properties may include, for example, the refractive index and light transmission coefficient of the outer casing and the thermally conductive liquid. In addition, the refractive index of the optical coating film on the outer casing or other optical member may be obtained as well.

In operation 1304, an optical simulation model is established. The optical simulation model simulates the optical and geometric configuration of a light-emitting diode bulb with respect to optical analysis of a light-emitting diode bulb. In this example, the optical simulation model simulates the geometry and position of the light-emitting diode bulb component with an optical analysis of the far-field intensity of light emitted from one or more light-emitting diodes. An example of establishing an optical simulation model is provided at operation 1104 of Figure 3A above.

In operation 1306, the position of the diffuser light strip in the simulated housing is calculated. In this example, the position of the diffuser volume band is calculated based on the optical simulation model established in operation 1304 and the optical characteristics obtained in operation 1302. In particular, in this example, the optical simulation model is used to perform at least one optical analysis to obtain a far field intensity distribution in a designated region of the analog light emitting diode bulb. The optical analysis can include a ray tracing optical analysis that calculates a plurality of simulated light rays emitted by the one or more analog light emitting diodes Angle and strength. Light scattering, reflection and absorption can also be calculated as part of this optical analysis.

In the example provided below, the position of the diffuser is defined by a width and a position relative to the plurality of light emitting diodes. This position can also be specified using angular values or other dimensional values relative to the geometry of the housing.

With regard to operation 1306, various outer shell contour shapes can be used to perform a variety of analyses to achieve a variety of far field intensity distributions. Figure 10 depicts an illustrative result of a simulated diffuse band of light aligning on a simulated housing, as will be discussed in more detail later. To perform multiple analyses, the geometry of the diffuse body band and other parameters can be modified using optical modeling tools (eg, APEX), or again from other modeling software tools (eg, SolidWorks' solid modeling tools) Import the optical modeling tool.

The results of the various optical analyses can be compared to calculate the position of the diffuser band that is one of the light distribution profiles that contribute to the uniformity criteria. As mentioned earlier, this uniformity criterion may be based on the ENERGY STAR specification of the uniformity of the light distribution profile.

In operation 1308, the results are stored in computer memory. In some cases, the location of the diffuser light strip calculated in operation 1306 is stored in a computer readable computer including a dynamic random access memory (RAM), a hard disk storage medium, an optical storage medium, or the like. Take the memory. In some cases, the results of at least one optical analysis performed in operation 1306, including the geometry of other simulated bulbs, are stored in a computer readable memory. The stored results can be used to construct a luminescence A diode bulb includes a housing having a diffuser strip of light positioned at a location calculated in operation 1306. In some embodiments, the stored results can be used to fabricate a light-emitting diode bulb having an estimated light distribution profile that is predicted from an axis extending from the center of the outer casing to the apex of the outer casing. The light distribution profile does not deviate from the average by more than 20% from 0 to 135 degrees. In some embodiments, the stored results can be used to fabricate a light-emitting diode bulb having an estimated light distribution profile that does not deviate from the average value at 0 to 135 degrees. 18, 15, 14 or 11 percentage.

Figure 10 depicts a light emitting diode bulb having an exemplary diffuser strip that can be used to fabricate a light emitting diode bulb having a light distribution profile that meets the uniformity criteria. As shown in FIG. 10, the light emitting diode is positioned at a nominal angle of 9 degrees and a position of +3 mm.

For the purpose of analysis, the heat transfer liquid had a refractive index of 1.4015, the outer shell had a refractive index of 1.52, and the outer shell had a thickness of 3 mm. For all of the simulations provided herein, the simulations were normalized to 1 lumen per simulated light-emitting diode. The optical properties of the pedestal and support structure, including surface luminosity for simulated optical scattering, are also taken into account. Figure 13 depicts an exemplary bidirectional reflectance distribution function (BRDF) applied to a simulated support structure and a simulated pedestal.

Figure 11 depicts an illustrative result of a light-emitting diode bulb having a diffuser strip that is about 12.5 mm above the center of the plurality of light-emitting diodes and about 5.5 mm below. As shown in Figure 11 It is shown that a light-emitting diode bulb having a diffuser light strip located at this location has a uniform light distribution intensity uniformity of +/- 11% from the average intensity. Thus, the diffuser light strip at this location can be used to fabricate a light-emitting diode bulb having a light distribution profile that meets the ENERGY STAR uniformity criteria.

A light-emitting diode bulb having a diffuser strip of light at other locations may also have a projected light profile that meets the ENERGY STAR uniformity criteria. For example, a light-emitting diode lamp having a diffuser band of 5 mm to 15 mm above the center of a plurality of light-emitting diodes and 5 mm to 15 mm below can also be used to produce an ENERGY STAR uniformity. A standard light-emitting diode bulb. In other embodiments, the diffuser strip may be positioned more than 15 millimeters above the center of the plurality of light-emitting diodes and more than 15 millimeters below. In other embodiments, the diffuser strip may be positioned less than 5 millimeters above the center of the plurality of light-emitting diodes and less than 5 millimeters below.

5. Optimize light distribution based on multiple factors

As discussed above, the refractive index of the outer casing and the heat transfer liquid, the angle and position of the light emitting diode relative to the outer casing, and the position of the diffuser light band all affect how the light emitted from the light emitting diode is illuminated. The dipole bulb is transferred. One or more of these parameters can be optimized to produce a light emitting diode bulb having a projected light distribution profile that meets the uniformity criteria.

3D depicts an exemplary method 1000 for calculating one or more of the following parameters: an angle of at least one light emitting diode The height, the height of the at least one light-emitting diode, the contour shape of the outer casing, and the position of the diffuser light belt disposed on the outer casing provide a light-emitting diode bulb having a light distribution profile that satisfies the uniformity standard. Method 1000 can be used to calculate an optical configuration of a light emitting diode bulb having a light distribution profile that meets the energy star uniformity requirements.

In operation 1002, the optical properties of the outer casing and the thermally conductive liquid are obtained. Such optical properties may include, for example, the refractive index and light transmission coefficient of the outer casing and the thermally conductive liquid. In addition, the refractive index of the optical coating film on the outer casing or other optical member may be obtained as well.

In operation 1004, an optical simulation model is established. The optical simulation model simulates the optical and geometric configuration of a light-emitting diode bulb with respect to optical analysis of a light-emitting diode bulb. In this example, the optical simulation model simulates the geometry and position of the light-emitting diode bulb component with an optical analysis of the far-field intensity of light emitted from one or more light-emitting diodes. An example of establishing an optical simulation model is provided at operation 1104 of Figure 3A above.

In operation 1006, one or more of the following values are calculated: an angle of at least one light emitting diode, a height of at least one light emitting diode, a contour shape of the outer casing, and a diffuser light strip disposed on the outer casing position. In this example, the one or more values are calculated based on the optical simulation model established in operation 1004 and the optical characteristics obtained in operation 1002. In particular, in this example, the optical simulation model is used to perform at least one optical analysis to obtain a far field intensity distribution in a designated region of the analog light emitting diode bulb. The light The analytical analysis can include a ray tracing optical analysis that calculates the angle and intensity of the plurality of simulated light rays emitted by the one or more analog light emitting diodes. Light scattering, reflection and absorption can also be calculated as part of this optical analysis.

With regard to operation 1006, one or more of the following values can be varied: the angle and height of the light emitting diode, the contour shape of the outer casing, and the position of the diffuser strip to perform a variety of analyses. The results of various optical analyses can be compared to calculate the value of the light distribution profile that results in meeting the uniformity criteria. As mentioned earlier, this uniformity criterion may be based on the ENERGY STAR specification of the uniformity of the light distribution profile.

In operation 1008, the results are stored in computer memory. In some cases, one or more of the angle and height of the LEDs calculated in operation 1006, the contour shape of the housing, and the position of the diffuser strip are stored, including, dynamic random access. A computer readable memory of a memory (RAM), a hard disk storage medium, an optical storage medium, or the like. In some cases, the results of at least one optical analysis performed in operation 1006, including other simulated bulb geometries, are stored in a computer readable memory. The stored results can be used to construct a light emitting diode bulb based on the values calculated in operation 1006. In some embodiments, the stored results can be used to fabricate a light-emitting diode bulb having an estimated light distribution profile that is predicted from an axis extending from the center of the outer casing to the apex of the outer casing. The light distribution profile does not deviate from the average by more than 20% from 0 to 135 degrees. In some embodiments, the stored results can be used to make a haircut A photodiode bulb having an estimated light distribution profile that does not deviate from the average by more than 18, 15, 14 or 11 percent at 0 to 135 degrees.

Figure 12 depicts the results of an analysis of the measured light distribution from an exemplary simulated light-emitting diode bulb compared to an actual light-emitting diode bulb. The analog light-emitting diode bulb has a plurality of light-emitting diodes at a height of +3 mm from the nominal and 9 degrees. The analog light-emitting diode bulb also has a simulated outer casing having a distance of 26.8 mm from the center of the outer casing to the outer contour of the outer casing for a first portion of the outer casing located approximately 30 degrees from the apex of the outer casing, and for seating from the outer casing The third portion of the outer casing having an apex of about 100 degrees has a distance of 26.3 mm. The actual light-emitting diode bulb has a plurality of light-emitting diodes positioned at positions corresponding to the analog light-emitting diodes, and an outer casing having a contour shape corresponding to the contour shape of the simulated outer casing.

For the purpose of analysis, the heat transfer liquid had a refractive index of 1.4015, the outer shell had a refractive index of 1.52, and the outer shell had a thickness of 3 mm. The simulation was normalized to 1 lumen per simulated light-emitting diode. The optical properties of the pedestal and support structure, including surface luminosity for simulated optical scattering, are also taken into account. Figure 13 depicts an exemplary bidirectional reflectance distribution function (BRDF) applied to a simulated support structure and a simulated pedestal.

As shown in FIG. 12, the deviation from the average of the projected light distribution profiles of the simulated light-emitting diode bulbs roughly corresponds to the deviation from the average of the measured light distribution profiles of the actual light-emitting diode bulbs. Both analog and actual LED bulbs have a value from 0 to 135 degrees. A light distribution profile with a difference of more than 20%. In some cases, the actual light-emitting diode can produce light having a uniformity of light intensity distribution with a deviation of +14% and -15% compared to an average light intensity of 0 to 135 degrees.

While the features may be described in a particular embodiment, those skilled in the art will appreciate that the various features of the described embodiments may be combined. Furthermore, the plurality of facing lines described in one embodiment may exist separately.

100‧‧‧(liquid filled) light-emitting diode (LED) bulb

101‧‧‧ Shell

103‧‧‧Lighting diode

107‧‧‧Support structure

110‧‧‧Base

111‧‧‧Hot conductive liquid

115‧‧‧ terminal block

Claims (17)

  1. A computer implemented method for providing a light-emitting diode (LED) bulb having a light distribution profile satisfying a uniformity standard, the method comprising: obtaining a contour shape and a refractive index of a simulated casing; and obtaining a simulated heat transfer liquid Refractive index; establishing an optical simulation model of the light-emitting diode bulb, the optical simulation model having a plurality of analog light-emitting diodes, the plurality of analog light-emitting diode systems being disposed in the simulated housing, and the simulated heat transfer liquid system Between the plurality of analog light-emitting diodes and the interior of the analog casing; calculating one of an angle and a height of the at least one analog light-emitting diode of the plurality of analog light-emitting diodes relative to the outer casing The calculation is based on: the optical simulation model; the contour shape of the simulated outer casing and the refractive index; and the refractive index of the thermally conductive liquid, wherein the angle and the height cause an estimated light distribution profile when extended from The projected light distribution profile is averaged from 0 to 135 degrees from the center of the simulated housing to one axis of the apex of the simulated housing. Intensity varies 20 percent or less; storing said first calculated simulation of the angle and height of the light-emitting diode.
  2. The computer implemented method of claim 1, wherein the optical simulation model is adapted to perform from the plurality of analog light-emitting diodes One ray tracing optical analysis of the simulated light emitted by the analog light-emitting diode.
  3. A method of manufacturing a light-emitting diode bulb having a light distribution profile meeting a uniformity standard, the method comprising: obtaining a susceptor; obtaining a casing having a refractive index and a contour shape; Calculating the refractive index and the contour shape, and a refractive index of a heat transfer liquid to be disposed in the outer casing and between the plurality of light emitting diodes and the outer casing to calculate at least the plurality of light emitting diodes An angle and a height of a light-emitting diode, wherein the angle and the height cause an estimated light distribution profile, the projected light distribution profile when measured from an axis extending from a center of the outer casing to an apex of the outer casing Varying 20% or less with respect to an average light intensity at 0 to 135 degrees; positioning the plurality of light emitting diodes in the outer casing at the calculated angle and the calculated height; a shell is coupled to the base; and the outer shell is filled with the heat transfer liquid.
  4. A liquid-filled light-emitting diode (LED) bulb comprising: a base; an outer casing connected to the base; a plurality of light-emitting diodes connected to the base and disposed in the outer casing And a heat transfer liquid retained in the outer casing and disposed in the plurality Between the light-emitting diodes and the outer casing, wherein the plurality of light-emitting diodes are positioned between 3.5 mm and 10 mm from the center of the outer casing, and from 4 to 12 from the center line of the outer casing An angle between the degrees is positioned, and the light-emitting diode bulb has an estimated light distribution profile that is estimated relative to an average light intensity between 0 and 135 degrees when measured from the apex of the outer casing. Change 20% or less.
  5. A computer-implemented method for providing a light-emitting diode (LED) bulb having a light distribution profile that satisfies a uniformity standard, the method comprising: obtaining a refractive index of a simulated outer casing; and obtaining a refractive index of a simulated heat-conducting liquid Obtaining an angle and a height of the at least one analog light-emitting diode of the plurality of analog light-emitting diodes relative to the simulated outer casing; establishing an optical simulation model of the light-emitting diode bulb, the optical simulation model having the plurality of simulations a light emitting diode, the plurality of analog light emitting diode systems are disposed in the dummy housing, and the simulated heat conducting fluid system is disposed between the plurality of analog light emitting diodes and the interior of the analog housing; calculating the simulated housing a contour shape having at least two radii, the calculation being based on: the optical simulation model; the angle and the height of the at least one analog light-emitting diode; the refractive index of the simulated outer casing; and the heat transfer liquid The refractive index, Wherein the contour shape results in a predicted light distribution profile, the estimated light distribution profile being relative to an average light intensity at 0 to 135 degrees when measured from an axis extending from the center of the simulated casing to the apex of the simulated casing Change 20% or less; store the calculated contour shape of the simulated housing.
  6. The computer-implemented method of claim 5, wherein calculating the contour shape of the simulated housing comprises: obtaining a first radial limit of a first portion of the contour shape, the first portion being located from the simulated housing a vertex measurement between 0 degrees and 40 degrees; and a second radial limit of a second portion of the contour shape, the second portion being located 40 degrees from the vertex of the simulated outer casing Between 130 degrees; the contour shape is calculated based on the first and second radial limits.
  7. The computer-implemented method of claim 5, wherein calculating the contour shape of the simulated housing comprises: obtaining a first radial limit of a first portion of the contour shape, the first portion being located from the simulated housing The vertex is measured between 0 degrees and 40 degrees; a second radial limit of a second portion of the contour shape is obtained, the second portion being located at 40 degrees to 90 degrees from the vertex of the simulated outer casing Between degrees; obtaining a third radial limit of a third portion of the contour shape, the third portion being located at 90 degrees to 130 from the apex of the simulated outer casing Between degrees; and calculating the contour shape based on the first, second, and third radial limits.
  8. A method of fabricating a light-emitting diode bulb having a light distribution profile that satisfies a uniformity standard, the method comprising: obtaining a pedestal; calculating a contour shape of an outer casing having at least two radii, the calculation is based on: a refractive index of the outer casing; a refractive index of an analog heat-conducting liquid to be placed into the outer casing; an angle and a height of at least one of the plurality of analog light-emitting diodes to be disposed in the outer casing of the plurality of analog light-emitting diodes Wherein the contour shape of the outer casing results in a projected light distribution profile that, when measured from the apex of the outer casing, varies by 20 percent or less relative to the average light intensity at 0 to 135 degrees Obtaining an outer casing having the calculated contour shape; positioning the plurality of light emitting diodes in the outer casing; connecting the outer casing to the base; and filling the outer casing with the heat transfer liquid.
  9. A liquid-filled light-emitting diode (LED) bulb comprising: a base; an outer casing connected to the base; a plurality of light emitting diodes connected to the base and disposed in the outer casing; and a heat transfer liquid retained in the outer casing, wherein the outer casing has a contour shape, the contour shape having: the contour shape a first portion of the first portion to a center of the bulb, the first portion being tethered between 0 degrees and 40 degrees measured from the apex of the outer casing, a second portion of the contour shape being attached to the bulb a second distance of the center, the second portion being tied between 40 degrees and 130 degrees from the apex of the outer casing, wherein the first and second distances are different distances, and wherein the light is The polar bulb has an estimated light distribution profile that varies by 20 percent relative to the average light intensity at 0 to 135 degrees when measured from an axis extending from the center of the outer casing to the apex of the outer casing less.
  10. The liquid-filled light-emitting diode bulb of claim 9, wherein the first distance is about 27.5 mm and the second distance is about 26.5 mm.
  11. The liquid-filled light-emitting diode bulb of claim 9, wherein the first distance is about 26.8 mm and the second distance is about 26.3 mm.
  12. A liquid-filled light-emitting diode bulb according to claim 9 wherein the first distance is about 26.8 mm and the second distance is about 26.5 mm.
  13. A computer implemented method for providing a light-emitting diode (LED) bulb having a light distribution profile satisfying a uniformity standard, the method comprising: obtaining a contour shape and a refractive index of a simulated casing; and obtaining a simulated heat transfer liquid Refractive index; establishing an optical simulation model of the light-emitting diode bulb, the optical simulation model having a plurality of analog light-emitting diodes, the plurality of analog light-emitting diode systems being disposed in the simulated housing, and the simulated heat transfer liquid system Between the plurality of analog light-emitting diodes and the interior of the simulated housing; calculating a position of an analog diffuser strip disposed on the simulated housing, the calculation is based on: the optical simulation model; the simulation The contour shape of the outer casing and the refractive index; and the refractive index of the thermally conductive liquid, wherein the position of the simulated diffuser light strip results in a projected light distribution profile from when extending from the center of the simulated outer casing to the When the one-axis measurement of the apex of the simulated casing is performed, the predicted light distribution profile varies by 20% or less with respect to the average light intensity at 0 to 135 degrees; The analog memory of the band of light diffuser calculated position.
  14. A method of fabricating a light-emitting diode bulb having a light distribution profile that satisfies a uniformity standard, the method comprising: obtaining a susceptor; obtaining a housing having a refractive index and a contour shape; Refractive index and the contour shape, and will be set Calculating a position of a diffuser light strip in the outer casing and a refractive index of a heat conducting liquid between the plurality of light emitting diodes and the outer casing, wherein the position of the diffuser light strip causes a Estimating the light distribution profile, when measured from an axis extending from the center of the outer casing to the apex of the outer casing, the projected light distribution profile varies by 20 percent or less relative to the average light intensity at 0 to 135 degrees; The calculated position is disposed on a diffuser strip of light on the outer casing; the outer casing is coupled to the base; and the outer casing is filled with the thermally conductive liquid.
  15. A liquid-filled light-emitting diode (LED) bulb comprising: a base; an outer casing connected to the base; a plurality of light-emitting diodes connected to the base and disposed in the outer casing a diffuser light strip disposed in the outer casing at a position 10 mm above and 10 mm below the center of the plurality of light-emitting diodes; and a heat-conducting liquid retained in the outer casing and Arranging between the plurality of light-emitting diodes and the outer casing, wherein the light-emitting diode bulb has an estimated light distribution profile, which is estimated when measured from an axis extending from a center of the outer casing to an apex of the outer casing The light distribution profile varies by 20% or less with respect to the average light intensity at 0 to 135 degrees.
  16. A computer implemented method for providing a light-emitting diode (LED) bulb having a light distribution profile satisfying a uniformity standard, the method comprising: obtaining a contour shape and a refractive index of a simulated casing; and obtaining a simulated heat transfer liquid Refractive index; establishing an optical simulation model of the light-emitting diode bulb, the optical simulation model having a plurality of analog light-emitting diodes, the plurality of analog light-emitting diode systems being disposed in the simulated housing, and the simulated heat transfer liquid system setting Between the plurality of analog light-emitting diodes and the interior of the simulated casing; calculating one or more of the following: an angle of the at least one analog light-emitting diode of the plurality of analog light-emitting diodes relative to the outer casing And a height; a contour shape of the simulated casing, the contour shape having at least two radii; and a position of a diffuser light band, the calculation being based on: the optical simulation model; the refractive index of the simulated casing; The refractive index of the thermally conductive liquid, wherein the calculation results in a projected light distribution profile when extending from the center of the simulated housing to the mold When a vertex of the measurement axis of the housing, the expected light distribution profile relative to the average light intensity in the 0 to 135 degrees is varied 20 percent or less; storing the result of the calculation.
  17. A liquid-filled light-emitting diode (LED) bulb comprising: a base; an outer casing connected to the base; a plurality of light-emitting diodes connected to the base and disposed in the outer casing And a heat transfer liquid held in the outer casing and disposed between the plurality of light emitting diodes and the outer casing, wherein the plurality of light emitting diodes are positioned about 9 mm from the center of the outer casing And being positioned at an angle of about 11 degrees from a central axis of the outer casing; the outer casing having a contoured shape having a first portion of the contour shape to a center of the bulb of about 26.8 mm a distance, the first portion being located about 30 degrees from the apex of the outer casing, a second portion of the contour shape to a second distance of the center of the outer casing of about 26.3 mm, the second portion being located At about 100 degrees measured from the apex of the outer casing, and the light-emitting diode bulb has an estimated light distribution profile, the projected light when measured from an axis extending from the center of the outer casing to one of the vertices of the outer casing Distribution profile The average light intensity in the 0 to 135 degrees is varied 20 percent or less.
TW102128312A 2012-08-08 2013-08-07 LED bulb having a uniform light-distribution profile TW201420951A (en)

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US201261681123P true 2012-08-08 2012-08-08
US13/588,964 US20140043821A1 (en) 2012-08-08 2012-08-17 Led bulb having a uniform light-distribution profile
US201361772473P true 2013-03-04 2013-03-04
US13/842,855 US20140043822A1 (en) 2012-08-08 2013-03-15 Led bulb having a uniform light-distribution profile
US13/892,186 US20140334147A1 (en) 2013-05-10 2013-05-10 Led bulb with a gas medium having a uniform light-distribution profile

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