Patent Description:
<CIT> discloses an LED package including: a body unit; an LED chip mounted onto the body unit; lead frames mounted onto the body unit and electrically connected to the LED chip; and a reflection unit having a cavity to receive the LED chip therein and reflecting light emitted from the LED chip to the outside. Here, the reflection unit has a curved cross-section.

<CIT> discloses an LED array in a holder, wherein the LED array emits light through an aperture of the holder.

An LED device holder, an LED lighting system and a method of manufacturing an LED lighting system are described herein. An LED lighting system includes a holder defining an aperture. The aperture has a perimeter and a fillet adjacent the perimeter. The fillet has a radius greater than or equal to <NUM> and less than or equal to <NUM>. An LED array is mechanically coupled to the holder. The LED array has a light emitting surface exposed through the aperture.

Examples of different light illumination systems and/or light emitting diode ("LED") implementations will be described more fully hereinafter with reference to the accompanying drawings. These examples are not mutually exclusive, and features found in one example may be combined with features found in one or more other examples to achieve additional implementations. Accordingly, it will be understood that the examples shown in the accompanying drawings are provided for illustrative purposes only and they are not intended to limit the disclosure in any way.

It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms may be used to distinguish one element from another. For example, a first element may be termed a second element and a second element may be termed a first element without departing from the scope of the present invention. As used herein, the term "and/or" may include any and all combinations of one or more of the associated listed items.

It will be understood that when an element such as a layer, region, or substrate is referred to as being "on" or extending "onto" another element, it may be directly on or extend directly onto the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" or extending "directly onto" another element, there may be no intervening elements present. It will also be understood that when an element is referred to as being "connected" or "coupled" to another element, it may be directly connected or coupled to the other element and/or connected or coupled to the other element via one or more intervening elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present between the element and the other element. It will be understood that these terms are intended to encompass different orientations of the element in addition to any orientation depicted in the figures.

Relative terms such as "below," "above," "upper,", "lower," "horizontal" or "vertical" may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.

Further, whether the LEDs, LED arrays, electrical components and/or electronic components are housed on one, two or more electronics boards may also depend on design constraints and/or application.

The output from an LED device is generally concentrated, but the distribution may be broad and may, therefore, lack intensity over a distance. As a result, LED lamps and fixtures may incorporate one or more secondary optical elements, such as apertures and reflectors. Secondary optical elements may collect the light, magnify its intensity, direct it to a target surface, and shape the beam of light.

COB LED devices may be desirable due to their flexibility and low cost. However, traditional secondary optical elements, such as industry standard apertures, may reduce the efficiency of an LED system that uses a COB LED device as a light source.

Embodiments described herein provide for secondary optics for LED devices and methods of manufacture that may increase system efficiency. In one embodiment, secondary optics for a COB LED device are described that include at least an aperture with an adjacent fillet that increases system efficiency up to <NUM>%. While an example embodiment is described that is optimized for a particular COB LED, methods are described herein that may be used to optimize a radius of the fillet for various COB LED devices and other non-COB types of LED devices that include densely packed LED arrays.

<FIG> is a perspective view of a COB LED device <NUM>. In embodiments, the COB LED device <NUM> may be used as a light source in an LED lighting system. In the example illustrated in <FIG>, the COB LED device <NUM> has an outer perimeter <NUM>. In one embodiment, the outer perimeter <NUM> is a rectangular shape. However, the outer perimeter <NUM> may be other shapes, including, but not limited to, a circular or stadium shape. The COB LED device <NUM> may have a light emitting area <NUM> that includes an array of light emitting elements. The array of light emitting elements may be arranged on a single substrate and covered by an encapsulant within a ring <NUM> or other frame structure. In embodiments, the encapsulant may include a wavelength conversion material that converts one or more wavelengths of light emitted by the light emitting elements to one or more other wavelengths of light.

The COB LED device <NUM> may be any type of COB LED device, such as the LUMILEDS® CoB Gen <NUM> (e.g., L2C5-22901208E1500) <NUM> lm LED (hereinafter Lumileds CoB Gen). The Lumileds CoB Gen has a circular shaped light emitting area with a diameter of approximately <NUM> and a ring having a diameter of approximately <NUM>. An example of an LED lighting system is described herein that uses the Lumileds CoB Gen as an example LED device for which the secondary optics in the LED light system are optimized. However, as will be clear, the secondary optics can be optimized, using methods described herein, for any type of LED device with a densely packed LED array. The secondary optics may include, for example, apertures and reflectors that may collect light, magnify its intensity, direct it to the target surface, and shape the beam of light.

<FIG> are diagrams of an example LED device holder <NUM>. The example LED device holder <NUM> includes an inner section <NUM> that defines an aperture <NUM>. The inner section <NUM> of the holder <NUM> defining the aperture <NUM> has a defined height and a flat inner surface <NUM>. Given the flat inner surface <NUM>, when the LED device holder <NUM> is incorporated in an LED lighting system having a COB LED device as the light source, the overall efficiency of the LED lighting system may decrease.

<FIG> are diagrams of an example LED device holder <NUM> according to the invention. The example LED device holder <NUM> illustrated in <FIG> includes an outer section <NUM>, a bevel portion <NUM>, and an inner section <NUM>. The size and shape of the outer section <NUM> are defined by an outer wall <NUM> and a top portion <NUM>. In the illustrated example, the outer wall <NUM> of the outer section <NUM> has a cylindrical shape. However, the outer wall <NUM> of the outer section <NUM> may be any suitable shape, including, but not limited to, a rectangular shape.

The inner section <NUM> may have a top portion <NUM> and a bottom portion <NUM>. In the illustrated example, the top portion <NUM> of the inner section <NUM> sits lower than the top portion <NUM> of the outer section <NUM>. The bottom portion <NUM> of the inner section <NUM> defines an aperture <NUM>. In embodiments, the inner section <NUM> is circular shaped and defines a circular aperture <NUM>. However, the inner section <NUM> and the aperture <NUM> may have any suitable shape.

The bevel portion <NUM> of the holder <NUM> is situated between the outer section <NUM> and the inner section <NUM>. The bevel portion <NUM> mechanically couples the top portion <NUM> of the outer section <NUM> and the top portion <NUM> of the inner section <NUM> and slopes inward in such a way that allows the top portion <NUM> of the inner section <NUM> to sit below the top portion <NUM> of the outer section <NUM>.

The LED device holder <NUM> further includes first and second mounts 312A and 312B. The first mount 312A protrudes from a segment of the top portion <NUM> of the inner section <NUM> and the second mount 312B is located opposite the first mount 312B and protrudes from another segment of the top portion <NUM> of the inner section <NUM>. The mounts 312A, 312B each have an opening in which a screw may be inserted. The mounts 312A, 312B may be configured to align with holes in a heat sink or other element (not shown) for attachment. The mounts 312A, 312B may also be configured for securing the LED device holder <NUM> to a COB or other LED device, such as by being arranged to align with openings or indentations in the COB or other LED device. Accordingly, when the LED device holder <NUM> is attached to a heat sink or other element by inserting screws into the mounts 312A, 312B, the COB or other LED device may be secured in place and aligned such that the light emitting area is exposed through the aperture <NUM> in LED device holder <NUM>. While two mounts 312A and 312B are illustrated in <FIG>, one or more mounts <NUM> may be used consistent with the embodiments described herein.

In embodiments where the LED device is a COB LED device, such as the COB LED device illustrated in <FIG>, a diameter of the aperture <NUM> may be slightly larger than a diameter of the ring <NUM> containing the light emitting area <NUM>. In embodiments, the ratio of the diameter of the aperture <NUM> to the diameter of the ring <NUM> may approximately <NUM>. For example, in a lighting system using the Lumileds CoB Gen as the light source, the light emitting area may have a diameter of approximately <NUM>. As such, in such an embodiment, the aperture <NUM> may have a diameter of approximately <NUM>.

In contrast to the flat inner surface <NUM> of the inner section <NUM> of the LED device holder <NUM> of <FIG>, the upper portion <NUM> of the inner section <NUM> of the LED device holder <NUM> of <FIG> has a fillet shape. In embodiments, the fillet shape has a radius <NUM> greater than <NUM> and equal to or less than <NUM> for light emitting areas having diameters greater than or equal to <NUM> and less than or equal to <NUM>. For the Lumileds CoB Gen device having a mid-range light emitting area diameter of <NUM>, the radius <NUM> of the fillet shape may be optimal at <NUM>. For smaller light emitting surface diameters, the optimal radius <NUM> of the fillet shape may go down to approximately <NUM>. For larger light emitting surface diameters, the optimal radius <NUM> of the fillet shape may be similar to the Lumileds CoB Gen device (e.g., approximately <NUM>). The fillet shaped upper surface (also referred to herein as a fillet) may be diffusely or specularly reflective in order to aid in re-directing/re-focusing the light emitted by the COB or other LED device in conjunction with the secondary optics.

In embodiments, the LED device holder <NUM> may be disposed on top of the COB or other LED device. The COB or other LED device may be sized and configured in such a way that the aperture <NUM> aligns with the light emitting area of the COB or other LED device. As described above, the COB or other LED device may be secured to the LED device holder <NUM> when the LED device holder <NUM> is attached to a heat sink or other element by inserting screws into the mounts 312A, 312B. The COB or other LED device may alternatively or additionally be secured to the LED device holder <NUM> in other ways. For example, the LED device holder <NUM> may comprise at least one tab located and sized to mate in a male - female fashion with the COB or other LED device to join the LED device holder <NUM> and the COB or other LED device.

In embodiments, the aperture <NUM> may be filled with a polymer to protect the light emitting area of the COB or other LED device. In embodiments, the polymer may be polybutylene terephthalate (PBT) glass. PBT glass is electrically insulating and mechanically strong and may, thereby, provide protection and insulation to the COB or other LED device.

As mentioned above, the secondary optics in an LED lighting system may include an aperture and a reflector. <FIG> illustrate example LED lighting systems that include a reflector <NUM> disposed on top of the COB or other LED device and the LED device holder <NUM>. The reflector <NUM> may concentrate a beam of light exiting the aperture <NUM>. In embodiments, the reflector <NUM> may be formed from aluminum.

The illustrated reflector <NUM> has an opening <NUM> and curved sidewalls <NUM> that curve outwardly away from the opening <NUM>. In embodiments, the reflector opening <NUM> is circular shaped. However, the opening <NUM> may have any suitable shape (e.g., based on a shape of the light emitting area of the COB or other LED device that is mechanically coupled to the LED device holder <NUM>). At least a lower portion of the reflector <NUM> may be shaped to match the LED device holder <NUM>. For example, at least the lower portion of the reflector may have approximately the same slope as the bevel portion <NUM> of the LED device holder <NUM> so as to allow the reflector to slide smoothly into the LED device holder <NUM>.

In embodiments, the reflector opening <NUM> and the aperture <NUM> of the LED device holder <NUM> may have the same diameter and may be configured to align such that the light emitted from the light emitting area <NUM> may travel through the aperture <NUM> and the reflector opening <NUM>. The curved sidewalls <NUM> of the reflector <NUM> may reflect light exiting the LED lighting system so that the light exiting the LED light system is concentrated to form a generally circular beam.

In the example illustrated in <FIG>, the bevel portion <NUM> of LED device holder <NUM> includes at least one slot <NUM>. Further, in the example illustrated in <FIG>, the reflector <NUM> includes at least one tab <NUM> on an outer surface of the reflector sidewalls <NUM>. The reflector tab <NUM> and the holder slot <NUM> may be located and sized to mate in a male - female fashion to join the LED device holder <NUM> and the reflector <NUM>. In the embodiments illustrated in <FIG> and <FIG>, two slots and two tabs are shown. However, one of ordinary skill in the art will understand that more or less tabs and slots may be included consistent with the embodiments described herein.

In another embodiment (not shown), at least one slot may be provided in the reflector sidewalls <NUM> and at least one tab may be provided on the bevel portion of the LED device holder <NUM>. The slots and tabs may be located and sized to mate in a male - female fashion to join the LED device holder <NUM> and the reflector <NUM>.

As mentioned above, the radius of the fillet can be optimized to, for example, optimize the efficiency of the LED lighting system. Methods for optimizing the radius of the fillet shape are described below. While one specific example is described, one of ordinary skill in the art will recognize that the methods can be used to optimize the radius of the fillet for any type of COB or other LED device having an array of densely packed light emitting elements.

<FIG> is a flow diagram <NUM> of an example method of manufacturing an LED lighting system. In the example illustrated in <FIG>, the method includes determining at least one optical property of a material (<NUM>). The at least one optical property may be, for example, at least one of the reflectivity and refractivity of the material. In embodiments, the reflectivity or refractivity of the LED device holder may be measured. This may be done using, for example, any type of suitable sensor, such as integrating spheres, which may or may not be communicatively coupled to a computer system. In other embodiments, the optical property of the material may be entered as a user input into a computer system via a user interface or may already be pre-programmed into the computer system and/or software. For example, software and/or hardware may provide a graphic user interface (GUI) through which a user may select a material, and various optical properties of that material may already be known by the software and/or hardware.

A model of an LED device holder may be generated (<NUM>). The generated model may be a computer-generated model. The model of the LED device holder may include an aperture and a fillet adjacent the aperture. The fillet may have a radius. In embodiments, an LED device holder may be measured and a computer-generated model may be generated based on the measurements (e.g., using a coordinate-measuring machine (CMM)). In other embodiments, a user may provide inputs to the computer system via one or more user inputs that may enable the computer system to generate and display the model.

Using the optical property and the generated model, a graph may be generated (<NUM>), for example, by increasing a value for the radius of the fillet and plotting the efficiency of the LED lighting system for each radius value up to a maximum efficiency. This may be done, for example, by generating a computer model of the lighting system including the LED device holder and selected LED array and running simulations for each radius value. If desired, the simulation can be run based on materials with different optical properties. Example graphs for the Lumileds CoB Gen are provided in <FIG> and described in detail below.

An optimal radius may be chosen (<NUM>) based on the generated graph (or graphs). For example, a radius corresponding to the maximum efficiency or an optimal efficiency taking into account other competing considerations if necessary or desired may be chosen. In embodiments, the selection may be made by a user looking at the graph displayed on a display, and the user may choose a radius that intersects with the most optimal output characteristic(s) of the LED lighting system (e.g., maximum system efficiency). In other embodiments, the computer system may select a radius based on criteria entered by a user using a user interface or pre-programmed and stored in storage or memory.

An LED device holder that is formed from the selected material and that has a fillet with the selected radius may be attached to an LED array (<NUM>). The LED device holder formed from the selected material and having the selected radius may be manufactured, obtained or otherwise selected. If the LED device holder is manufactured, it may be manufactured using an automated fabrication system, such as one communicatively coupled to the same or different computer system that was used to generate the graph. In other embodiments, the LED device holder may be manufactured using any suitable method, device or system, including preparing different portions of the LED device holder using different methods, devices and/or systems and then assembling them to form an LED device holder.

<FIG> is a diagram of an example system <NUM> that may be used to implement all or some of the method of <FIG>. The system <NUM> may be, for example, a personal computer, a handheld device, optionally a personal computer or handheld device communicatively coupled to one or more sensors, or optionally an automated assembly system. In the example illustrated in <FIG>, the system <NUM> includes a computer system <NUM> that may include a processor <NUM>, a memory <NUM>, storage <NUM>, one or more input devices <NUM>, one or more output devices <NUM>, and an optional communication interface <NUM>. The computer system <NUM> may also optionally include an input driver and an output driver (not shown) that drive the one or more input devices <NUM> and one or more output devices <NUM>. The optional communication interface <NUM> may be communicatively coupled to one or more sensors <NUM> and/or a fabrication system <NUM> in some embodiments. One of ordinary skill in the art will understand that system <NUM> may include additional components not shown in <FIG>.

The processor <NUM> may include a central processing unit (CPU), a graphics processing unit (GPU), a CPU and GPU, and/or one or more processor cores. The memory <NUM> may include a volatile or non-volatile memory, for example, random access memory (RAM), dynamic RAM, or a cache. The storage <NUM> may include a fixed or removable storage, for example, a hard disk drive, a solid state drive, an optical disk, or a flash drive. The one or more input devices <NUM> may include, for example, a keyboard, a keypad, a touch screen, a touch pad, a detector, a microphone, an accelerometer, a gyroscope, a biometric scanner, and/or a network connection (e.g., a wireless local area network card for transmission and/or reception of wireless IEEE <NUM> signals). The one or more output devices <NUM> may include, for example, a display, a speaker, a printer, a haptic feedback device, one or more lights, an antenna, and/or a network connection (e.g., a wireless local area network card for transmission and/or reception of wireless IEEE <NUM> signals).

The optional input driver may communicate with the processor <NUM> and the input devices <NUM> and enable the processor <NUM> to receive input from the input devices <NUM>. The optional output driver may communicate with the processor <NUM> and the output devices <NUM> and enable the processor <NUM> to send output to the output devices <NUM>. As the input driver and the output driver are optional components, the computer system <NUM> will operate in the same manner if the input driver and the output driver are not present.

The communication interface <NUM> may be any device capable of receiving inputs from, and providing outputs to, peripheral devices. In embodiments, the communication interface may one or a combination of a modem, wireless router, or USB connector.

The one or more sensors <NUM> may be any type of sensor and, in particular, may be sensors used to measure the reflectivity of the LED device holder, such as a spectrometer. In such embodiments, the computer system <NUM> may control the sensors to measure the reflectivity of the LED device holder and provide the measurement to software running on the computer system <NUM> that may generate one or more graphs, such as mentioned above and described below in detail. In other embodiments, the sensors may be user operated and configured just to provide measurements to the computer system <NUM> without control by the computer system <NUM>.

The fabrication system <NUM> may be used to automate the entire manufacturing process for the LED device holder, if desired. As such, the fabrication system <NUM> may include any number of different components including robotic controls, robotic arms, gripping tools, conveyor belts, software, hardware and any other component used to manufacture the LED device holder under control of the computer system <NUM>. As mentioned above, the fabrication system is not required, and one of ordinary skill in the art would recognize that the computer system <NUM> may be used to generate and display the one or more graphs and the remaining portions of the methods described herein may be performed using any number of different manufacturing techniques, which may include some automated processes, some human implemented processes, or some combination thereof.

<FIG> is a graph <NUM> of LED lighting system efficiency v. fillet radius for the example Lumileds CoB Gen described above. The measured diffuse reflectivity of the LED device holder, in this example, was <NUM>% in <NUM>. As shown in the graph <NUM>, for an LED lighting system using the LED device holder <NUM> (e.g., fillet radius = <NUM>), the system efficiency is approximately <NUM>%. For the LED device holder <NUM> with an inner portion <NUM> having a fillet radius greater than <NUM> and equal to or less than <NUM>, the efficiency increases with incremental increases in the fillet radius up to a maximum of approximately <NUM>. When the fillet radius of the inner portion <NUM> of holder <NUM> is <NUM>, the efficiency of the LED lighting system is approximately <NUM>%. Accordingly, in this example, <NUM> would be chosen as the fillet radius for the inner portion of the LED device holder and may result in an increase in the overall LED lighting system efficiency of approximately <NUM>%.

<FIG>, <FIG>, <FIG> and <FIG> are graphs showing output flux, maximum intensity and full width at half maximum (FWHM) data for incremental increases of the fillet radius for the Lumileds CoB Gen example. In embodiments, one or more of these graphs may alternatively or additionally be used to select the optimal radius of the fillet.

As illustrated in the graph 800A of <FIG>, the flux increases as the fillet radius is increased from <NUM> to approximately <NUM>. For example, when the fillet radius <NUM> of inner portion <NUM> of the LED device holder <NUM> is <NUM>, the flux increases by <NUM>% as compared to the LED device holder <NUM> with the inner portion <NUM> having a fillet radius of <NUM>.

As illustrated in the graph 800B of <FIG>, the maximum intensity increases as the fillet radius is increased from <NUM> to approximately <NUM>. For example, when the fillet radius <NUM> of the inner portion <NUM> of LED device holder <NUM> is <NUM>, the maximum intensity increases by <NUM>% as compared to the LED device holder <NUM> with the inner portion <NUM> having a fillet radius of <NUM>.

As illustrated in the graph 800C of <FIG>, the full width at half maximum (FWHM) increases as the fillet radius is increased from <NUM> to approximately <NUM>. For example, when the fillet radius <NUM> of inner portion <NUM> of the LED device holder <NUM> is <NUM>, the FWHM increases by approximately <NUM>% as compared to the LED device holder <NUM> with the inner portion <NUM> having a fillet radius of <NUM>.

As illustrated in the graph 800D of <FIG>, the FWHM at <NUM>% (FW10%M) remains relatively constant as the fillet radius is increased from <NUM> to approximately <NUM>. Thus, the fillet radius has minimal impact on FW10%M of the example LED device system.

<FIG> is a diagram 900A of the far field intensity radiation pattern of an LED lighting system incorporating the Lumileds CoB Gen LED device and the LED device holder <NUM> (e.g., fillet radius = <NUM>). <FIG> is a diagram 900B of the far field intensity radiation pattern of an LED lighting system incorporating the Lumileds CoB Gen LED device and the LED device holder <NUM> with the selected fillet radius of <NUM>. As can be seen by comparing the diagrams illustrated in <FIG> and <FIG>, the total power, system efficiency and maximum intensity are improved for the LED lighting system using the LED device holder <NUM> with the selected fillet radius of <NUM>.

Claim 1:
A light emitting diode (LED) device holder (<NUM>) comprising:
an outer section (<NUM>); and
an inner section (<NUM>) mechanically coupled to the outer section (<NUM>), the inner section (<NUM>) defining an aperture (<NUM>) having a perimeter,
characterized in that
a portion of the inner section (<NUM>) adjacent the aperture (<NUM>) having a convex fillet shape with a radius (<NUM>) greater than or equal to <NUM> and less than or equal to <NUM>.