Source: https://patents.google.com/patent/US8033692B2/en
Timestamp: 2018-06-19 06:29:27
Document Index: 145494142

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60']

US8033692B2 - Lighting device - Google Patents
US8033692B2
US8033692B2 US11751982 US75198207A US8033692B2 US 8033692 B2 US8033692 B2 US 8033692B2 US 11751982 US11751982 US 11751982 US 75198207 A US75198207 A US 75198207A US 8033692 B2 US8033692 B2 US 8033692B2
US11751982
US20070274080A1 (en )
This application claims the benefit of U.S. Provisional Patent Application No. 60/802,709, filed May 23, 2006, the entirety of which is incorporated herein by reference.
This application claims the benefit of U.S. Provisional Patent Application No. 60/808,702, filed May 26, 2006, the entirety of which is incorporated herein by reference.
The present invention relates to a lighting device, in particular, a device which includes one or more solid state light emitters. The present invention also relates to a method of making a lighting device, in particular, a device which includes one or more solid state light emitters.
In addition, as compared to the normal lifetimes of solid state light emitters, e.g., light emitting diodes, incandescent light bulbs have relatively short lifetimes, i.e., typically about 750-1000 hours. In comparison, light emitting diodes, for example, have typical lifetimes between 50,000 and 70,000 hours). Fluorescent bulbs have longer lifetimes (e.g., 10,000-20,000 hours) than incandescent lights, but provide less favorable color reproduction.
Color reproduction is typically measured using the Color Rendering Index (CRI Ra). CRI Ra is a modified average of the relative measurements of how the color rendition of an illumination system compares to that of a reference radiator when illuminating eight reference colors, i.e., it is a relative measure of the shift in surface color of an object when lit by a particular lamp. The CRI Ra equals 100 if the color coordinates of a set of test colors being illuminated by the illumination system are the same as the coordinates of the same test colors being irradiated by the reference radiator. Daylight has a high CRI (Ra of approximately 100), with incandescent bulbs also being relatively close (Ra greater than 95), and fluorescent lighting being less accurate (typical Ra of 70-80). Certain types of specialized lighting have very low CRI (e.g., mercury vapor or sodium lamps, have Ra as low as about 40 or even lower).
Accordingly, for these and other reasons, efforts have been ongoing to develop ways by which light emitting diodes and other solid state light emitters can be used in place of incandescent lights, fluorescent lights and other light-generating devices in a wide variety of applications. In addition, where light emitting diodes (or other solid state light emitters) are already being used, efforts are ongoing to provide light emitting diodes (or other solid state light emitters) which are improved, e.g., with respect to energy efficiency, color rendering index (CRI Ra), contrast, efficacy (1 m/W), cost, and/or duration of service.
A variety of solid state light emitters are well-known. Light emitting diodes are well-known semiconductor devices that convert electrical current into light. A wide variety of light emitting diodes are used in increasingly diverse fields for an ever-expanding range of purposes.
The expression “light emitting diode” is used herein to refer to the basic semiconductor diode structure (i.e., the chip). The commonly recognized and commercially available “LED” that is sold (for example) in electronics stores typically represents a “packaged” device made up of a number of parts. These packaged devices typically include a semiconductor based light emitting diode such as (but not limited to) those described in U.S. Pat. Nos. 4,918,487; 5,631,190; and 5,912,477, various wire connections, and a package that encapsulates the light emitting diode.
Because light that is perceived as white is necessarily a blend of light of two or more colors (or wavelengths), no single light emitting diode junction has been developed that can produce white light. “White” light emitting diode lamps have been produced which have a light emitting diode pixel formed of respective red, green and blue light emitting diodes. Another “white” LED lamp which has been produced includes (1) a light emitting diode which generates blue light and (2) a luminescent material (e.g., a phosphor) that emits yellow light in response to excitation by light emitted by the light emitting diode, whereby the blue light and the yellow light, when mixed, produce light that is perceived as white light.
In addition, the blending of primary colors to produce combinations of non-primary colors is generally well understood in this and other arts.
Inclusion of luminescent materials in LED devices has been accomplished by adding the luminescent materials to a clear or transparent encapsulant material (e.g., epoxy-based, silicone-based, glass-based or metal oxide-based material) as discussed above, for example by a blending or coating process.
As noted above, “white LED lamps” (i.e., lights which are perceived as being white or near-white) have been investigated as potential replacements for white incandescent lamps. A representative example of a white LED lamp includes a package of a blue light emitting diode chip, made of indium gallium nitride (InGaN) or gallium nitride (GaN), coated with a phosphor such as YAG. In such an LED lamp, the blue light emitting diode chip produces an emission with a wavelength of about 450 nm, and the phosphor produces yellow fluorescence with a peak wavelength of about 550 nm on receiving that emission. For instance, in some designs, white light emitting diode lamps are fabricated by forming a ceramic phosphor layer on the output surface of a blue light-emitting semiconductor light emitting diode. Part of the blue ray emitted from the light emitting diode chip passes through the phosphor, while part of the blue ray emitted from the light emitting diode chip is absorbed by the phosphor, which becomes excited and emits a yellow ray. The part of the blue light emitted by the light emitting diode which is transmitted through the phosphor is mixed with the yellow light emitted by the phosphor. The viewer perceives the mixture of blue and yellow light as white light.
There is an ongoing need for a high efficiency solid-state white light source that combines the efficiency and long life of white LED lamps with an acceptable color temperature and good color rendering index, good contrast, a wide gamut and simple control circuitry.
In a first aspect of the present invention, there is provided a lighting device comprising at least one plural cavity element and a plurality of solid state light emitters, in which the plural cavity element has at least two optical cavities (each comprising a concave region in the plural cavity element) and in which at least one of the solid state light emitters is present in each of at least two of the optical cavities.
In a second aspect of the present invention, there is provided a lighting device comprising at least one encapsulant region, at least one plural cavity element (having at least two optical cavities), and a plurality of solid state light emitters, at least one solid state light emitter being present in each of at least two of the optical cavities. In this aspect of the present invention, at least a portion of the plural cavity element, with the solid state light emitters mounted on optical cavities of the plural cavity element, is surrounded by the encapsulant region. In some embodiments according to this aspect of the invention, the plural cavity element is embedded in the encapsulant region.
In some embodiments according to the present invention, at least one broad spectrum light emitter (defined below) is provided in a first of the optical cavities and at least one narrow spectrum light emitter (defined below) is provided in a second of the optical cavities.
In some embodiments according to the present invention, walls of each of the optical cavities are reflective.
In some embodiments according to the present invention, the plural cavity element comprises a first surface, the first surface being substantially planar, the first surface having a surface area which is at least five times as large as a combined surface area of the solid state light emitters. In some such embodiments, each of the optical cavities formed in the plural cavity element comprises a substantially planar mounting surface on which at least one of the solid state light emitters is mounted.
In some embodiments according to the present invention, the plural cavity element comprises a first side and a second side, the first side comprises a substantially planar first surface and a plurality of substantially flat mounting surfaces, at least one of the solid state light emitters is mounted on each of the mounting surfaces, each of the mounting surfaces is substantially coplanar, and the first surface and the mounting surfaces together comprise not less than 75% of a surface area of the first side of the plural cavity element.
FIG. 5 is a cross-sectional view of the embodiment shown in FIG. 4, taken along the plane V-V.
FIG. 6 depicts a second embodiment of a lighting device according to the present invention.
FIG. 7 is a cross-sectional view of another embodiment of a lighting device according to the present invention.
As noted above, in the first aspect of the present invention, there is provided a lighting device comprising at least one plural cavity element having at least two optical cavities, and a plurality of solid state light emitters, at least one solid state light emitter being present in each of at least two of the optical cavities.
In the second aspect of the present invention, there is provided a lighting device comprising at least one encapsulant region, at least one plural cavity element (having at least two optical cavities), and a plurality of solid state light emitters, at least one solid state light emitter being present in each of at least two of the optical cavities.
The plural cavity element can comprise any suitable structure which includes a plurality of optical cavities, each comprising a concave region in the plural cavity element. Persons skilled in the art can readily envision a wide variety of materials out of which the plural cavity element can be made. For example, in general, any material which has been used to make cup reflectors for LEDs can be employed in making the plural cavity element. Such materials include any of the materials which can be used to make leadframes (persons of skill in the art are familiar with a variety of materials which can be used to make leadframes) and/or which can be “stamped” to form such an element (persons of skill in the art are familiar with such materials and with “stamping” such materials). For instance, representative examples of materials out of which the plural cavity element can be made include silver-plated copper and silver-plated steel (and other metallic materials which can optionally be overmolded, on their sides and/or bottoms, with a reflective surface). Conversely, the plural cavity element can be made from an insulating material (e.g., Amodel, which is aluminum which has been anodized, steel with a ceramic coating, etc.), upon which conductive traces can be formed. The expression “conductive trace”, as used herein, refers to a structure which comprises a conductive portion, and may further include any other structure, e.g., one or more insulating layers.
The cavities formed in the plural cavity element can generally be of any desired concave shape. Persons of skill in the art are familiar with shaping cup reflectors in order to obtain favorable properties, particularly with regard to extracting the maximum amount of light from the light emitter contained within the cup, and the principles involved in such design of cup reflectors can be applied to the design of the cavities in the plural cavity element according to the present invention.
In some embodiments of the present invention, each of the cavities in a plural cavity element has substantially the same shape.
As used herein, the term “substantially,” e.g., in the expressions “substantially planar”, “substantially flat”, “substantially coplanar”, “substantially the same shape”, “substantially transparent”, means at least about 90% correspondence with the feature recited, e.g.:
the expressions “substantially planar” and “substantially flat”, as used herein, mean that at least 90% of the points in the surface which is characterized as being substantially flat are located on one of or between a pair of planes which are parallel and which are spaced from each other by a distance of not more than 5% of the largest dimension of the surface;
the expression “substantially coplanar”, as used herein, means that at least 90% of the points in each of the surfaces which are characterized as being substantially coplanar are located on one of or between a pair of planes which are parallel and which are spaced from each other by a distance of not more than 5% of the largest dimension of the surface;
the expression “substantially the same shape”, as used herein, means that angles and radii of curvature defined by respective surfaces on the respective items which are characterized as being substantially the same shape differ by not more than 5%;
the expression “substantially transparent”, as used herein, means that the structure which is characterized as being substantially transparent allows passage of at least 90% of the light having a wavelength within the range emitted by the solid state light emitter.
The expression “saturated”, as used herein, means having a purity of at least 85%, the term “purity” having a well-known meaning to persons skilled in the art, and procedures for calculating purity being well-known to those of skill in the art.
In some embodiments of the present invention, at least one of the walls of at least one of the cavities in the plural cavity element is reflective.
In some embodiments of the present invention, the plural cavity element comprises a first, substantially planar, surface in which the concave cavities are formed. In some such embodiments, the first surface has a surface area which is at least five times as large as a combined surface area of the solid state light emitters contained in the cavities.
In some embodiments of the present invention, at least one (and, in some embodiments, all) of the optical cavities formed in the plural cavity element comprises a substantially planar mounting surface on which at least one of the solid state light emitters is mounted.
In some embodiments of the present invention, each optical cavity in the plural cavity element comprises a substantially flat mounting surface, and each of the mounting surfaces are substantially coplanar.
In some embodiments of the present invention, the plural cavity element comprises a first side and a second side, the first side comprising a substantially planar first surface and a plurality of substantially flat mounting surfaces, at least one solid state light emitter being mounted on each of the mounting surfaces, each of the mounting surfaces being substantially coplanar, the first surface and the mounting surfaces together comprising not less than 75% of a surface area of the first side of the plural cavity element.
As noted above, in the first and second aspects of the present invention, the lighting device comprises a plurality of solid state light emitters. Any desired solid state light emitter or emitters can be employed in accordance with the present invention. Persons of skill in the art are aware of, and have ready access to, a wide variety of such emitters. Such solid state light emitters include inorganic and organic light emitters. Examples of types of such light emitters include light emitting diodes (inorganic or organic), laser diodes, thin film electroluminescent devices, light emitting polymers (LEPs), and polymer light emitting diodes (PLEDs), a variety of each of which are well-known in the art. Because these various solid state light emitters are well-known in the art, it is not necessary to describe them in detail, nor is it necessary to describe the materials out of which such devices are made.
The respective light emitters can be similar to one another, different from one another or any combination (i.e., there can be a plurality of solid state light emitters of one type, or one or more solid state light emitters of each of two or more types). The light emitters can each be of similar size, or one or more of the light emitters can be of a size which differs from one or more of the other light emitters (e.g., a lighting device can include a chip which emits blue light which is of a size of 1 square millimeter, and a chip which emits red light which is of a size of 300 square micrometers).
In some embodiments according to the present invention, each solid state light emitter is mounted in a separate optical cavity. In other embodiments according to the present invention, at least one optical cavity has more than one solid state light emitter (each of which emits light of similar wavelength, or one or more of which emit light of wavelength which differs from that of light emitted by one or more other solid state light emitter in the same cavity) mounted therein.
In some embodiments according to the present invention, one or more lumiphor is provided in at least one of the optical cavities. In most cases, only one or more solid state light emitters of a single color (and typically only a single solid state light emitter) is provided in any optical cavity (or cavities) in which one or more lumiphor is provided, in order to avoid undesired interaction between light from any solid state light emitter and such lumiphor(s). For example, where a particular optical cavity includes a light emitting diode which emits blue light and a lumiphor (e.g., a broad spectrum phosphor such as YAG:Ce) which, upon excitation, produces yellow light (whereby, as indicated above, light exiting the optical cavity is perceived as being white), in most cases, it would be desirable to not include in the same optical cavity any light emitting diodes which emit a color which differs from the blue light (it is possible to include multiple solid state light emitters which emit light of similar wavelength(s) in a single cavity, with one or more of the solid state light emitters being at least partially covered by one or more lumiphors, e.g., multiple blue LEDs covered by a single glob or multiple globs of phosphor-containing material(s)).
In some embodiments according to the present invention, at least one of the optical cavities can have mounted therein plural solid state light emitters of a single color or of plural colors. In some such embodiments, at least one of the optical cavities can have mounted therein two or more saturated solid state light emitters of a single color or of plural colors.
As noted above, in some embodiments according to the present invention, at least one broad spectrum light emitter is provided in a first of the optical cavities and at least one narrow spectrum light emitter is provided in a second of the optical cavities. In some such embodiments, there are provided a plurality of optical cavities in which at least one broad spectrum light emitter (wherein the respective broad spectrum light emitters in the different optical cavities are all similar, are all different or are any possible combination of similar and different) is provided and a plurality of optical cavities in which at least one narrow spectrum light emitter (wherein the respective narrow spectrum light emitters in the different optical cavities are all similar, are all different or are any possible combination of similar and different) is provided (optionally, there may further be other optical cavities in which other light emitters are provided).
The expression “broad spectrum light emitter” is used herein to refer to a light emitter which emits unsaturated light, i.e., light that has less than 85% purity. Such light emitter may comprise a single solid state light emitter and a single lumiphor, or a single solid state light emitter and a plurality of lumiphors, or a plurality of solid state light emitters and a single lumiphor, or a plurality of solid state light emitters and a plurality of lumiphors.
The expression “narrow spectrum light emitter” is used herein to refer to a light emitter which emits saturated light, i.e., light having a purity of 85% or higher (e.g., high purity red, cyan or blue, such as nearly monochromatic light emitters).
In some embodiments according to the present invention, a broad spectrum light emitter can comprise two or more sources of visible light (each of the sources of visible light being independently selected from among solid state light emitters and luminescent materials) which, if mixed in the absence of any other light, would produce a combined illumination which would be perceived as white or near-white. The expression “white light generating sources” is used herein to refer to combinations of two or more sources of visible light which produce light which, if combined in the absence of any other light, would produce an illumination which would be perceived as white or near-white.
In some embodiments according to the present invention, there is provided a lighting device in which a broad spectrum light emitter is provided in one or more optical cavities, and one or more saturated sources of light are provided in one or more other optical cavities, in order to adjust the color point (i.e., x, y chromaticity coordinates on the CIE chart) and/or to improve the CRI Ra of the light emitted from the lighting device.
In some embodiments according to the present invention, there is provided a lighting device in which a white light generating source having poor CRI (e.g., Ra of 75 or less) is provided in one or more optical cavities, and one or more saturated sources of light are provided in one or more other optical cavities, in order to increase the CRI Ra of the light from the white light generating source.
In accordance with the present invention, by providing different solid state light emitters in different optical cavities of a single plural cavity element, as opposed to providing the different emitters in separate and distinct cup reflectors, blending of the light emitted from the respective solid state light emitters (and from any lumiphors) can be achieved in a shorter distance.
In accordance with the second aspect of the present invention, by providing different solid state light emitters in different optical cavities of a single plural cavity element embedded in a single encapsulant region, as opposed to providing the different emitters in separate and distinct packages, blending of the light emitted from the respective solid state light emitters (and from any lumiphors) can be achieved in a shorter distance.
In accordance with the present invention, by putting different light emitters in separate optical cavities, undesired interaction of light from the respective light emitters (and from any lumiphors) in the near field is avoided or reduced.
In accordance with the second aspect of the present invention, by providing different solid state light emitters in different optical cavities of a single plural cavity element embedded in a single encapsulant region, light emissions from each of the light emitters within the encapsulant region have a high degree of interaction in the far field (e.g., farther than 5 cm away from the light emitters).
In some embodiments according to the present invention, there is further provided the ability to control and/or adjust each solid state light emitter in the device by analog or digitally. Persons of skill in the art would readily be able to provide appropriate circuitry by which each solid state light emitter in devices according to the present invention can be independently controlled and/or adjusted.
In some embodiments of the second aspect of the present invention, the light exiting the respective solid state light emitters (and any lumiphors) contained in an encapsulant region is approximately 80% mixed by the time the light exits the encapsulant region, and such light is nearly completely mixed 5 cm away from the surface of the encapsulant region.
Specific examples of combinations of light emitters and/or lumiphors are described in U.S. Patent Application No. 60/752,555, filed Dec. 21, 2005, entitled “Lighting Device and Lighting Method” (inventors: Antony Paul Van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference).
Other representative examples of suitable combinations of light emissions include the following:
Specific examples of combinations of light emitters and/or lumiphors are described in:
(a) U.S. Patent Application No. 60/752,555, filed Dec. 21, 2005, entitled “Lighting Device and Lighting Method” (inventors: Antony Paul Van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference,
(b) U.S. Patent Application No. 60/793,524, filed Apr. 20, 2006, entitled “Lighting Device” (inventors: Antony Paul Van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference, and
(c) U.S. Patent Application No. 60/793,518, filed Apr. 20, 2006, entitled “Lighting Device” (inventors: Antony Paul Van de Ven and Gerald H. Negley), the entirety of which is hereby incorporated by reference.
Included among such combinations of light emitters and/or lumiphors are:
(1) a combination including:
a first group of light emitting diodes;
a second group of light emitting diodes;
each of the first group of light emitting diodes, if illuminated, would emit light having a peak wavelength in the range of from 430 nm to 480 nm;
each of the first group of lumiphors, if excited, would emit light having a dominant wavelength in the range of from about 555 nm to about 585 nm; and
each of the second group of light emitting diodes, if illuminated, would emit light having a dominant wavelength in the range of from 600 nm to 630 nm;
(2) a combination including:
a second group of lumiphors; and
a third group of light emitting diodes;
each of the first group of light emitting diodes and each of the second group of light emitting diodes, if illuminated, would emit light having a peak wavelength in the range of from 430 nm to 480 nm;
each of the first group of lumiphors and each of the second group of lumiphors, if excited, would emit light having a dominant wavelength in the range of from about 555 nm to about 585 nm; and
if each of the first group of light emitting diodes is illuminated and each of the first group of lumiphors is excited, a mixture of light emitted from the first group of light emitting diodes and the first group of lumiphors would, in the absence of any additional light, have a first group mixed illumination corresponding to a first point on a 1931 CIE Chromaticity Diagram, the first point having a first correlated color temperature;
if each of the second group of light emitting diodes is illuminated and each of the second group of lumiphors is excited, a mixture of light emitted from the second group of light emitting diodes and the second group of lumiphors would, in the absence of any additional light, have a second group mixed illumination corresponding to a second point on a 1931 CIE Chromaticity Diagram, the second point has a second correlated color temperature, the first correlated color temperature differs from the second correlated color temperature by at least 500K; and
(3) a combination including:
each of the first group of lumiphors, if excited, would emit light having a dominant wavelength in the range of from about 555 nm to about 585 nm;
each of the second group of light emitting diodes, if illuminated, would emit light having a dominant wavelength in the range of from 600 nm to 630 nm; and
if each of the first group of light emitting diodes is illuminated and each of the first group of lumiphors is excited, a mixture of light emitted from the first group of light emitting diodes and the first group of lumiphors would, in the absence of any additional light, have a first group mixed illumination having x, y color coordinates which are within an area on a 1931 CIE Chromaticity Diagram enclosed by first, second, third, fourth and fifth line segments, the first line segment connecting a first point to a second point, the second line segment connecting the second point to a third point, the third line segment connecting the third point to a fourth point, the fourth line segment connecting the fourth point to a fifth point, and the fifth line segment connecting the fifth point to the first point, the first point having x, y coordinates of 0.32, 0.40, the second point having x, y coordinates of 0.36, 0.48, the third point having x, y coordinates of 0.43, 0.45, the fourth point having x, y coordinates of 0.42, 0.42, and the fifth point having x, y coordinates of 0.36, 0.38; and
(4) a combination including:
if each of the first group of light emitting diodes is illuminated and each of the first group of lumiphors is excited, a mixture of light emitted from the first group of light emitting diodes and the first group of lumiphors would have a first group mixed illumination corresponding to a first point on a 1931 CIE Chromaticity Diagram, the first point having a first correlated color temperature;
if each of the second group of light emitting diodes is illuminated and each of the second group of lumiphors is excited, a mixture of light emitted from the second group of light emitting diodes and the second group of lumiphors would have a second group mixed illumination corresponding to a second point on a 1931 CIE Chromaticity Diagram, the second point has a second correlated color temperature, the first correlated color temperature differs from the second correlated color temperature by at least 500K;
each of the third group of light emitting diodes, if illuminated, would emit light having a dominant wavelength in the range of from 600 nm to 630 nm; and
if each of the first group of light emitting diodes is illuminated, each of the first group of lumiphors is excited, each of the second group of light emitting diodes is excited and each of the second group of lumiphors is excited, a mixture of light emitted from the first group of light emitting diodes, the first group of lumiphors, the second group of light emitting diodes and the second group of lumiphors, in the absence of any other light, would have a first group-second group mixed illumination which, in the absence of any other light, would have x, y color coordinates which are within an area on a 1931 CIE Chromaticity Diagram enclosed by first, second, third, fourth and fifth line segments, the first line segment connecting a first point to a second point, the second line segment connecting the second point to a third point, the third line segment connecting the third point to a fourth point, the fourth line segment connecting the fourth point to a fifth point, and the fifth line segment connecting the fifth point to the first point, the first point having x, y coordinates of 0.32, 0.40, the second point having x, y coordinates of 0.36, 0.48, the third point having x, y coordinates of 0.43, 0.45, the fourth point having x, y coordinates of 0.42, 0.42, and the fifth point having x, y coordinates of 0.36, 0.38.
each of the second group of light emitting diodes, if illuminated, would emit light having a dominant wavelength in the range of from 610 nm to 630 nm;
each of the first group of light emitting diodes and each of the second group of light emitting diodes, if illuminated, would emit light having a peak wavelength in the range of from 430 mm to 480 nm;
a second group of light emitting diodes; and
a third group of light emitting diodes,
if each of the first group of light emitting diodes is illuminated and each of the first group of lumiphors is excited, a mixture of light emitted from the first group of light emitting diodes and the first group of lumiphors would, in the absence of any additional light, have a first group mixed illumination having x, y color coordinates which are within an area on a 1931 CIE Chromaticity Diagram enclosed by first, second, third and fourth line segments, the first line segment connecting a first point to a second point, the second line segment connecting the second point to a third point, the third line segment connecting the third point to a fourth point, and the fourth line segment connecting the fourth point to the first point, the first point having x, y coordinates of 0.30, 0.27, the second point having x, y coordinates of 0.30, 0.37, the third point having x, y coordinates of 0.34, 0.27, and the fourth point having x, y coordinates of 0.34, 0.37;
each of the third group of light emitting diodes, if illuminated, would emit light having a dominant wavelength in the range of from 490 nm to 510 nm;
each of the third group of light emitting diodes, if illuminated, would emit light having a dominant wavelength in the range of from 520 nm to 550 nm;
(5) a combination including:
a third group of light emitting diodes
each of the third group of light emitting diodes, if illuminated, would emit light having a peak wavelength in the range of from 430 nm to 480 nm;
(6) a combination including:
a second group of lumiphors;
a third group of light emitting diodes; and
a fourth group of light emitting diodes;
each of the third group of light emitting diodes, if illuminated, would emit light having a dominant wavelength in the range of from 610 nm to 630 nm;
each of the fourth group of light emitting diodes, if illuminated, would emit light having a peak wavelength in the range of from 430 nm to 480 nm;
These combinations listed above enable mixing of the desired spectrum to achieve light that is perceived as white, on or within 10 (or 20, or 40) MacAdam ellipses from the blackbody curve (in some cases on or within 5 MacAdam ellipses from the blackbody curve, and in some cases on or within 2 MacAdam ellipses from the blackbody curve), while achieving high color rendering indices (greater than 85).
As noted above, in the first and second aspects of the present invention, the lighting device comprises an encapsulant region. Persons of skill in the art are familiar with, and have easy access to, a wide variety of materials which are suitable for use in making an encapsulant region for a packaged LED, and any such materials can, if desired, be employed. For example, two well-known representative classes of materials out of which the encapsulant region can be constructed include epoxies and silicones.
Persons of skill in the art are also familiar with a wide variety of suitable shapes for the encapsulant region, and the encapsulant region(s) in the device according to the present invention can be of any such shape. Persons of skill in the art are also familiar with various ways to make a packaged device incorporating the various elements described herein in connection with the present invention. Accordingly, further description of materials for use in making the encapsulant region, shapes for the encapsulant region and methods of making the devices described herein is not needed.
Any suitable structure or structures can be employed to provide power to the solid state light emitters, and persons of skill in the art are familiar with and can devise a wide variety of such structures. One representative example of such a structure is a leadframe with one or more wires connected to the light emitter, which is a structure with which persons of skill in the art are very familiar. Skilled artisans are also familiar with materials which are used for making leadframes (representative examples of such materials including copper and steel materials which can be “stamped” to form the leadframes) and for making wires.
As noted above, in some embodiments according to the present invention, the lighting device further comprises at least one lumiphor (i.e., luminescence region or luminescent element which comprises at least one luminescent material). The one or more luminescent materials, when provided, can be in any desired form and can be selected from among phosphors, scintillators, day glow tapes, inks which glow in the visible spectrum upon illumination with ultraviolet light, etc. The luminescent element can, if desired, be embedded in a resin (i.e., a polymeric matrix), such as a silicone material, an epoxy, a substantially transparent glass or a metal oxide material. The expression “lumiphor”, as used herein, refers to any luminescent element, i.e., any element which includes a luminescent material, a variety of which are readily available and well-known to those skilled in the art.
The one or more lumiphors can individually be any lumiphor, a wide variety of which, as noted above, are known to those skilled in the art. For example, the or each lumiphor can comprise (or can consist essentially of, or can consist of) one or more phosphor. The or each of the one or more lumiphors can, if desired, further comprise (or consist essentially of, or consist of) one or more highly transmissive (e.g., transparent or substantially transparent, or somewhat diffuse) binder, e.g., made of epoxy, silicone, glass, metal oxide or any other suitable material (for example, in any given lumiphor comprising one or more binder, one or more phosphor can be dispersed within the one or more binder). For example, the thicker the lumiphor, in general, the lower the weight percentage of the phosphor can be. Representative examples of the weight percentage of phosphor include from about 3.3 weight percent up to about 20 weight percent, although, as indicated above, depending on the overall thickness of the lumiphor, the weight percentage of the phosphor could be generally any value, e.g., from 0.1 weight percent to 100 weight percent (e.g., a lumiphor formed by subjecting pure phosphor to a hot isostatic pressing procedure).
In some embodiments according to the first aspect of the present invention, the lighting device is shaped and sized so as to correspond with the shape and size of conventional lighting devices, e.g., currently, 5 mm LED packages, 3 mm LED packages, 7 mm LED packages, 10 mm LED packages and 12 mm LED packages, the sizes and shapes of which are well-known to those skilled in the art.
One or more brightness enhancement films can optionally further be included in the lighting devices according to this aspect of the present invention. Such films are well-known in the art and are readily available. Brightness enhancement films (e.g., BEF films commercially available from 3M) are optional—when employed, they provide a more directional light source by limiting the acceptance angle. Light not “accepted” is recycled by the highly reflective light source enclosure. Preferably, the brightness enhancement films (which can optionally be replaced by one or more extraction films, such as by WFT), if employed, are optimized to limit the viewing angle of the emitted source and to increase the probability of extracting light on the first (or earliest possible) pass.
In addition, one or more scattering elements (e.g., layers) can optionally be included in the lighting devices according to this aspect of the present invention. The scattering element can be included in a lumiphor, and/or a separate scattering element can be provided. A wide variety of separate scattering elements and combined luminescent and scattering elements are well known to those of skill in the art, and any such elements can be employed in the lighting devices of the present invention.
Representative examples of arrangements of lighting devices, schemes for mounting lighting devices, apparatus for supplying electricity to lighting devices, housings for lighting devices, fixtures for lighting devices and power supplies for lighting devices, all of which are suitable for the lighting devices of the present invention, are described in U.S. Patent Application No. 60/752,753, filed on Dec. 21, 2005, entitled “Lighting Device” (inventors: Gerald H. Negley, Antony Paul Van de Ven and Neal Hunter), the entirety of which is hereby incorporated by reference, and in U.S. Patent Application No. 60/798,446, filed on May 5, 2006, entitled “Lighting Device” (inventor: Antony Paul Van de Ven and Neal Hunter), the entirety of which is hereby incorporated by reference.
FIG. 4 is a top view of an embodiment of a lighting device 10 according to the first aspect of the present invention. Referring to FIG. 4, the lighting device 10 includes a plural cavity element 11 which has three concave optical cavities 12, 13, 14, each containing a respective light emitting diode 15, 16, 17 (the light emitting diode 15 is shown in FIG. 5). A lumiphor 18 is also present in the optical cavity 12.
The plural cavity element comprises a first surface 31 which is substantially planar. The first surface 31 has a surface area which is more than five times as large as a combined surface area of the light emitting diodes 15, 16, 17 (i.e., the surface areas of the surfaces (of the light emitting diodes 15, 16, 17) which face upward in FIG. 5).
Each of the optical cavities 12, 13, 14 comprises a substantially planar mounting surface 32, 33, 34, respectively, on which the respective light emitting diodes 15, 16, 17 are mounted.
Referring to FIG. 5, the plural cavity element comprises a first side 35 and a second side 36, the first side comprising the first surface 31 and the mounting surfaces 32, 33, 34. The mounting surfaces 32, 33, 34 are substantially coplanar. The first surface and the mounting surfaces together comprise not less than 75% of the surface area of the first side of the plural cavity element.
FIG. 6 is a cross-sectional view of an embodiment of a lighting device 20 according to the second aspect of the present invention. Referring to FIG. 6, the lighting device 20 includes a plural cavity element 21 which has three optical cavities (22, 23 and a third cavity, not visible in this view), each containing a respective light emitting diode (25, 26 and a third light emitting diode, not visible in this view). A lumiphor 28 is also present in the optical cavity 22. The plural cavity element 21 is surrounded by (and embedded in) an encapsulant region 29.
FIG. 7 is a cross-sectional view of another embodiment of a lighting device 40 according to the second aspect of the present invention. Referring to FIG. 7, the lighting device 40 includes a plural cavity element 41 which has three optical cavities (42, 43 and a third cavity, not visible in this view), each containing a respective light emitting diode (45, 46 and a third light emitting diode, not visible in this view). A lumiphor 48 is also present in the optical cavity 42. The plural cavity element 41 is surrounded by (and embedded in) an encapsulant region 49. The lighting device 40 further includes a scattering element 51 (in the form of a layer). A variety of scattering elements are well-known to persons skilled in the art, and any such scattering element can be employed in any of the devices according to the present invention. Persons skilled in the art can readily make such scattering elements, one example of a suitable way to provide a scattering element being by multiple casting to improve mixing.
Other representative embodiments according to the present invention are described below:
(1) a plural cavity element having at least one of a first type of optical cavity and at least one of a second type of optical cavity, the first type of optical cavity having mounted therein a blue light emitting diode and a yellow phosphor (e.g., YAG), the second type of optical cavity having mounted therein a red light emitting diode;
(2) a plural cavity element having at least one of a first type of optical cavity and at least one of a second type of optical cavity, the first type of optical cavity having mounted therein a blue light emitting diode and a yellow phosphor (e.g., YAG), the second type of optical cavity having mounted therein a blue light emitting diode;
(3) a plural cavity element having at least one of a first type of optical cavity, at least one of a second type of optical cavity and at least one of a third type of optical cavity, the first type of optical cavity having mounted therein a yellow light emitting diode, the second type of optical cavity having mounted therein a blue light emitting diode, the third type of optical cavity having mounted therein a red light emitting diode;
(4) a plural cavity element having at least one of a first type of optical cavity, at least one of a second type of optical cavity and at least one of a third type of optical cavity, the first type of optical cavity having mounted therein a blue light emitting diode with a yellow phosphor, the second type of optical cavity having mounted therein a blue light emitting diode, the third type of optical cavity having mounted therein a red light emitting diode;
(5) a plural cavity element having at least one of a first type of optical cavity, at least one of a second type of optical cavity and at least one of a third type of optical cavity, the first type of optical cavity having mounted therein a red light emitting diode, the second type of optical cavity having mounted therein a green light emitting diode, the third type of optical cavity having mounted therein a blue light emitting diode;
(6) a plural cavity element having at least one of a first type of optical cavity, at least one of a second type of optical cavity and at least one of a third type of optical cavity, the first type of optical cavity having mounted therein a light emitting diode and a green phosphor, the second type of optical cavity having mounted therein a red light emitting diode, the third type of optical cavity having mounted therein a blue light emitting diode;
(7) a plural cavity element having at least one of a first type of optical cavity and at least one of a second type of optical cavity, the first type of optical cavity having mounted therein a blue light emitting diode and a green phosphor, the second type of optical cavity having mounted therein a red light emitting diode;
(8) a plural cavity element having at least one of a first type of optical cavity, at least one of a second type of optical cavity and at least one of a third type of optical cavity, the first type of optical cavity having mounted therein a cyan light emitting diode, the second type of optical cavity having mounted therein an orange light emitting diode, the third type of optical cavity having mounted therein a “white” light emitting diode;
(9) a plural cavity element having at least one of a first type of optical cavity, at least one of a second type of optical cavity and at least one of a third type of optical cavity, the first type of optical cavity having mounted therein a cyan light emitting diode, the second type of optical cavity having mounted therein a red light emitting diode, the third type of optical cavity having mounted therein a “white” light emitting diode;
(10) a plural cavity element having at least one of a first type of optical cavity, at least one of a second type of optical cavity and at least one of a third type of optical cavity, the first type of optical cavity having mounted therein a light emitting diode and a yellow phosphor, the second type of optical cavity having mounted therein a red light emitting diode, the third type of optical cavity having mounted therein a cyan light emitting diode;
(11) a plural cavity element having at least one of a first type of optical cavity and at least one of a second type of optical cavity, the first type of optical cavity having mounted therein a cyan light emitting diode and a yellow phosphor, the second type of optical cavity having mounted therein a red light emitting diode; and
(12) packaged devices including any of the above plural cavities (i.e., (1)-(11)) embedded in an encapsulant region.
at least one plural cavity element, said plural cavity element having at least two optical cavities, each of said optical cavities comprising a concave region in said plural cavity element;
a plurality of solid state light emitters, at least one of said solid state light emitters present in each of at least two of said optical cavities; and
an encapsulant region, said plural cavity element completely surrounded by said encapsulant region.
2. A lighting device as recited in claim 1, wherein walls of each of said optical cavities are reflective.
3. A lighting device as recited in claim 1, wherein said plural cavity element comprises a first surface, said first surface substantially planar, said first surface having a surface area which is at least five times as large as a combined surface area of said solid state light emitters.
4. A lighting device as recited in claim 3, wherein each of said optical cavities formed in said plural cavity element comprises a substantially planar mounting surface on which at least one of said solid state light emitters is mounted.
5. A lighting device as recited in claim 1, wherein said plural cavity element comprises a first side and a second side, said first side comprising a substantially planar first surface and a plurality of substantially flat mounting surfaces, at least one of said solid state light emitters mounted on each of said mounting surfaces, each of said mounting surfaces substantially coplanar, said first surface and said mounting surfaces together comprising not less than 75% of a surface area of said first side of said plural cavity element.
6. A lighting device as recited in claim 1, wherein at least one broad spectrum solid state light emitter is provided in a first of said optical cavities and at least one narrow spectrum solid state light emitter is provided in a second of said optical cavities.
7. A lighting device as recited in claim 1, further comprising at least one scattering element.
8. A lighting device as recited in claim 1, further comprising at least one scattering element, said scattering element included in said encapsulant region.
at least one encapsulant region, at least a portion of said plural cavity element surrounded by said encapsulant region,
wherein if each of said plurality of solid state light emitters is illuminated, light exiting said encapsulant region which was emitted from said plurality of solid state light emitters would be at least 80% mixed.
10. A lighting device as recited in claim 9, wherein said plural cavity element is completely surrounded by said encapsulant region.
11. A lighting device as recited in claim 9, further comprising at least one scattering element.
12. A lighting device as recited in claim 11, wherein said scattering element is included in said encapsulant region.
13. A lighting device as recited in claim 9, wherein walls of each of said optical cavities are reflective.
14. A lighting device as recited in claim 9, wherein said plural cavity element comprises a first surface, said first surface substantially planar, said first surface having a surface area which is at least five times as large as a combined surface area of said solid state light emitters.
15. A lighting device as recited in claim 14, wherein each of said optical cavities formed in said plural cavity element comprises a substantially planar mounting surface on which at least one of said solid state light emitters is mounted.
16. A lighting device as recited in claim 9, wherein said plural cavity element comprises a first side and a second side, said first side comprising a substantially planar first surface and a plurality of substantially flat mounting surfaces, at least one of said solid state light emitters mounted on each of said mounting surfaces, each of said mounting surfaces substantially coplanar, said first surface and said mounting surfaces together comprising not less than 75% of a surface area of said first side of said plural cavity element.
17. A lighting device as recited in claim 9, wherein at least one broad spectrum solid state light emitter is provided in a first of said optical cavities and at least one narrow spectrum solid state light emitter is provided in a second of said optical cavities.
18. A lighting device as recited in claim 1, wherein if each of said plurality of solid state light emitters is illuminated, mixed light exiting said encapsulant region would, in the absence of any additional light, have x, y coordinates on a 1931 CIE Chromaticity Diagram which define a point which is within twenty MacAdam ellipses of at least one point on the blackbody locus on a 1931 CIE Chromaticity Diagram.
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