The described embodiments relate to illumination devices that include Light Emitting Diodes (LEDs).
The use of LEDs in general lighting is becoming more common and more prevalent. Illumination devices that combine a number of LEDs may be used to improve the color quality and rendering, but suffer from spatial and/or angular variations in the color. Moreover, illumination devices that use LEDs sometimes are limited in the resulting emission patterns. Reflectors are sometimes used with LED based illumination devices to produce a more pleasing emission pattern.
A reflector housing is detachably coupled to an LED based illumination device and includes a flange having a surface facing the environment illuminated by the LED based illumination device. The reflector housing further includes a reflector having an input port that receives light emitted from the LED based illumination device and an output port through which light passes toward the environment. At least one sensor, such as a sensor for occupancy, ambient light, temperature, ultrasound, vibration, pressure, gyro-scope, magnetic field, gas detector, smoke detector, or a camera, microphone, visual indicator, or photodetector, is coupled to the flange such that at least a portion of the sensor faces the environment illuminated by the LED based illumination device. A reflector interface module configured to receive at least one signal from the sensor is coupled to the reflector housing. Additionally, a communications interface subsystem is configured to transmit and receive communications signals to and from the reflector housing.
In one implementation, an apparatus includes a reflector housing configured to be detachably coupled to an LED based illumination device that is configured to illuminate an environment. The reflector housing includes a flange having a surface facing the environment illuminated by the LED based illumination device; and a reflector having an input port configured to receive a first amount of light emitted from the LED based illumination device and an output port through which light passes toward the environment. The reflector is configured to redirect at least a portion of the first amount of light emitted from the LED based illumination device toward the output port. A sensor is coupled to the flange of the reflector housing such that at least a portion of the sensor faces the environment illuminated by the LED based illumination device. A reflector interface module coupled to the reflector housing is configured to receive at least one signal from the sensor. In addition, a first communications interface subsystem is configured to transmit and receive communications signals to and from the reflector housing.
The accompanying drawings, where like numerals indicate like components, illustrate embodiments of the invention.
Reference will now be made in detail to background examples and some embodiments of the invention, examples of which are illustrated in the accompanying drawings.
As depicted in
As illustrated in
LEDs 102 can emit different or the same color light, either by direct emission or by phosphor conversion, e.g., where phosphor layers are applied to the LEDs as part of the LED package. The illumination device 100 may use any combination of colored LEDs 102, such as red, green, blue, ultraviolet, amber, or cyan, or the LEDs 102 may all produce the same color light. Some or all of the LEDs 102 may produce white light. In addition, the LEDs 102 may emit polarized light or non-polarized light and LED based illumination device 100 may use any combination of polarized or non-polarized LEDs. In some embodiments, LEDs 102 emit either blue or UV light because of the efficiency of LEDs emitting in these wavelength ranges. The light emitted from the illumination device 100 has a desired color when LEDs 102 are used in combination with wavelength converting materials on transmissive plate 174, for example. By tuning the chemical and/or physical (such as thickness and concentration) properties of the wavelength converting materials and the geometric properties of the coatings on the surface of transmissive plate 174, specific color properties of light output by LED based illumination device 100 may be specified, e.g., color point, color temperature, and color rendering index (CRI).
For purposes of this patent document, a wavelength converting material is any single chemical compound or mixture of different chemical compounds that performs a color conversion function, e.g., absorbs an amount of light of one peak wavelength, and in response, emits an amount of light at another peak wavelength.
By way of example, phosphors may be chosen from the set denoted by the following chemical formulas: Y3Al5O12:Ce, (also known as YAG:Ce, or simply YAG) (Y,Gd)3Al5O12:Ce, CaS:Eu, SrS:Eu, SrGa2S4:Eu, Ca3(Sc,Mg)2Si3O12:Ce, Ca3Sc2Si3O12:Ce, Ca3Sc2O4:Ce, Ba3Si6O12N2:Eu, (Sr,Ca)AlSiN3:Eu, CaAlSiN3:Eu, CaAlSi(ON)3:Eu, Ba2SiO4:Eu, Sr2SiO4:Eu, Ca2SiO4:Eu, CaSc2O4:Ce, CaSi2O2N2:Eu, SrSi2O2N2:Eu, BaSi2O2N2:Eu, Ca5(PO4)3Cl:Eu, Ba5(PO4)3Cl:Eu, Cs2CaP2O7, Cs2SrP2O7, Lu3Al5O12:Ce, Ca8Mg(SiO4)4Cl2:Eu, Sr8Mg(SiO4)4Cl2:Eu, La3Si6N11:Ce, Y3Ga5O12:Ce, Gd3Ga5O12:Ce, Tb3Al5O12:Ce, Tb3Ga5O12:Ce, and Lu3Ga5O12:Ce.
In one example, the adjustment of color point of the illumination device may be accomplished by adding or removing wavelength converting material from transmissive plate 174. In one embodiment a red emitting phosphor 179 such as an alkaline earth oxy silicon nitride covers a portion of transmissive plate 174, and a yellow emitting phosphor 178 such as a YAG phosphor covers another portion of transmissive plate 174.
In some embodiments, the phosphors are mixed in a suitable solvent medium with a binder and, optionally, a surfactant and a plasticizer. The resulting mixture is deposited by any of spraying, screen printing, blade coating, jetting, or other suitable means. By choosing the shape and height of the transmissive plate 174, and selecting which portions of transmissive plate 174 will be covered with a particular phosphor or not, and by optimization of the layer thickness and concentration of a phosphor layer on the surfaces, the color point of the light emitted from the device can be tuned as desired.
In one example, a single type of wavelength converting material may be patterned on a portion of transmissive plate 174. By way of example, a red emitting phosphor 179 may be patterned on different areas of the transmissive plate 174 and a yellow emitting phosphor 178 may be patterned on other areas of transmissive plate 174. In some examples, the areas may be physically separated from one another. In some other examples, the areas may be adjacent to one another. The coverage and/or concentrations of the phosphors may be varied to produce different color temperatures. It should be understood that the coverage area of the red and/or the concentrations of the red and yellow phosphors will need to vary to produce the desired color temperatures if the light produced by the LEDs 102 varies. The color performance of the LEDs 102, red phosphor and the yellow phosphor may be measured and modified by any of adding or removing phosphor material based on performance so that the final assembled product produces the desired color temperature.
Transmissive plate 174 may be constructed from a suitable optically transmissive material (e.g., sapphire, quartz, alumina, crown glass, polycarbonate, and other plastics). Transmissive plate 174 is spaced above the light emitting surface of LEDs 102 by a clearance distance. In some embodiments, this is desirable to allow clearance for wire bond connections from the LED package submount to the active area of the LED. In some embodiments, a clearance of one millimeter or less is desirable to allow clearance for wire bond connections. In some other embodiments, a clearance of two hundred microns or less is desirable to enhance light extraction from the LEDs 102.
In some other embodiments, the clearance distance may be determined by the size of the LED 102. For example, the size of the LED 102 may be characterized by the length dimension of any side of a single, square shaped active die area. In some other examples, the size of the LED 102 may be characterized by the length dimension of any side of a rectangular shaped active die area. Some LEDs 102 include many active die areas (e.g., LED arrays). In these examples, the size of the LED 102 may be characterized by either the size of any individual die or by the size of the entire array. In some embodiments, the clearance should be less than the size of the LED 102. In some embodiments, the clearance should be less than twenty percent of the size of the LED 102. In some embodiments, the clearance should be less than five percent of the size of the LED. As the clearance is reduced, light extraction efficiency may be improved, but output beam uniformity may also degrade.
In some other embodiments, it is desirable to attach transmissive plate 174 directly to the surface of the LED 102. In this manner, the direct thermal contact between transmissive plate 174 and LEDs 102 promotes heat dissipation from LEDs 102. In some other embodiments, the space between mounting board 164 and transmissive plate 174 may be filled with a solid encapsulate material. By way of example, silicone may be used to fill the space. In some other embodiments, the space may be filled with a fluid to promote heat extraction from LEDs 102.
In the embodiment illustrated in
In some embodiments, multiple, stacked transmissive layers or plates are employed. Each transmissive plate includes different wavelength converting materials. For example, a transmissive plate including a wavelength converting material may be placed over another transmissive plate including a different wavelength converting material. In this manner, the color point of light emitted from LED based illumination device 100 may be tuned by replacing the different transmissive plates independently to achieve a desired color point. In some embodiments, the different transmissive plates may be placed in contact with each other to promote light extraction. In some other embodiments, the different transmissive plates may be separated by a distance to promote cooling of the transmissive layers. For example, airflow may be introduced through the space to cool the transmissive layers.
The mounting board 164 provides electrical connections to the attached LEDs 102. In one embodiment, the LEDs 102 are packaged LEDs, such as the Luxeon Rebel manufactured by Philips Lumileds Lighting. Other types of packaged LEDs may also be used, such as those manufactured by OSRAM (Ostar package), Luminus Devices (USA), Cree (USA), Nichia (Japan), or Tridonic (Austria). As defined herein, a packaged LED is an assembly of one or more LED die that contains electrical connections, such as wire bond connections or stud bumps, and possibly includes an optical element and thermal, mechanical, and electrical interfaces. The LEDs 102 may include a lens over the LED chips. Alternatively, LEDs without a lens may be used. LEDs without lenses may include protective layers, which may include phosphors. The phosphors can be applied as a dispersion in a binder, or applied as a separate plate. Each LED 102 includes at least one LED chip or die, which may be mounted on a submount. The LED chip typically has a size about 1 mm by 1 mm by 0.5 mm, but these dimensions may vary. In some embodiments, the LEDs 102 may include multiple chips. The multiple chips can emit light of similar or different colors, e.g., red, green, and blue. The LEDs 102 may emit polarized light or non-polarized light and LED based illumination device 100 may use any combination of polarized or non-polarized LEDs. In some embodiments, LEDs 102 emit either blue or UV light because of the efficiency of LEDs emitting in these wavelength ranges. In addition, different phosphor layers may be applied on different chips on the same submount. The submount may be ceramic or other appropriate material. The submount typically includes electrical contact pads on a bottom surface that are coupled to contacts on the mounting board 164. Alternatively, electrical bond wires may be used to electrically connect the chips to a mounting board. Along with electrical contact pads, the LEDs 102 may include thermal contact areas on the bottom surface of the submount through which heat generated by the LED chips can be extracted. The thermal contact areas are coupled to heat spreading layers on the mounting board 164. Heat spreading layers may be disposed on any of the top, bottom, or intermediate layers of mounting board 164. Heat spreading layers may be connected by vias that connect any of the top, bottom, and intermediate heat spreading layers.
In some embodiments, the mounting board 164 conducts heat generated by the LEDs 102 to the sides of the mounting board 164 and the bottom of the mounting board 164. In one example, the bottom of mounting board 164 may be thermally coupled to a heat sink 120 (shown in
Mounting board 164 includes electrical pads to which the electrical pads on the LEDs 102 are connected. The electrical pads are electrically connected by a metal, e.g., copper, trace to a contact, to which a wire, bridge or other external electrical source is connected. In some embodiments, the electrical pads may be vias through the mounting board 164 and the electrical connection is made on the opposite side, i.e., the bottom, of the board. Mounting board 164, as illustrated, is rectangular in dimension. However, in general, mounting board 164 may be configured in any suitable shape. LEDs 102 mounted to mounting board 164 may be arranged in different configurations on mounting board 164. In one example LEDs 102 are aligned in rows extending in the length dimension and in columns extending in the width dimension of mounting board 164. In another example, LEDs 102 are arranged in a hexagonally closely packed structure. In such an arrangement each LED is equidistant from each of its immediate neighbors. Such an arrangement is desirable to increase the uniformity and efficiency of emitted light.
In one aspect, a detachable reflector assembly including sensing and communication capability is detachably mounted to an LED based illumination device.
As depicted in
Reflector 201 includes an input port configured to receive a first amount of light emitted from the LED based illumination device 100 and an output port through which light passes toward the environment. The reflecting surface(s) of reflector 201 are configured to redirect at least a portion of the light emitted from the LED based illumination device toward the output port.
In some embodiments, signals generated by sensor 204A in combination with sensor interface electronics 205 are transmitted over conductor 208 to reflector interface module 203. The signals are communicated to the mounting board of LED based light engine 160 over the inductive coupling formed by conductors 207A-B. In some examples, the signals are further communicated to an electrical interface module 122 of LED based illumination device 100 over conductors 206. In some examples, elements of electrical interface module 122 may use these signals to generate control commands to change the illumination properties of LED based light engine 160.
In some embodiments, signals generated by sensor 204A in combination with sensor interface electronics 205 are transmitted over conductors 208 to reflector interface module 203. The signals are then communicated to electrical interface module 122 over an inductive coupling formed by conductors coiled on reflector interface module 203 and on electrical interface module 122. In some examples, elements of electrical interface module 122 may use these signals to generate control commands to change the illumination properties of LED based light engine 160.
In some embodiments, the inductive coupling is further configured to transmit electrical power between LED based illumination device and the reflector assembly 200. For example, as depicted in
In yet another further aspect, the reflector interface module 203 includes a power bus configured to supply power to the plurality of sensors coupled to the reflector housing. In this manner, reflector interface module 203 acts as a power supply to sensors attached to the reflector assembly 200.
Many different types of sensors may be mounted to flange 202. By way of non-limiting example, one or more occupancy sensors, ambient light sensors, temperature sensors, cameras, microphones, visual indicators such as low power LEDs, ultrasonic sensors, vibration sensors, pressure sensors, gyroscopic sensor, magnetic field sensor, gas detector, smoke detector and photodetectors may be mounted to flange 202. In general, the outwardly facing surface(s) of flange 202 is suitable for any sensor collecting data from the environment illuminated by LED based illumination device 100.
In addition, one or more sensors may be located in areas of the reflector housing that are not necessarily exposed to the environment illuminated by LED based illumination device 100. For example, one or more temperature sensors, vibration sensors, gyroscopic sensor, magnetic field sensor and pressure sensors may be located on the reflector housing to monitor environmental parameters such as temperature, etc. near LED based illumination device 100, e.g., between the flange 202 and the LED based illumination device 100. For example, a temperature sensor may be mounted close to electronic components of reflector interface module 203 to monitor operating temperatures to minimize component failure.
In yet another aspect, reflector assembly 200 includes a wireless communications interface subsystem configured to transmit and receive communications signals to and from the reflector assembly 200. The wireless communications interface subsystem includes a wireless transceiver 209 operable in accordance with a wireless communications protocol, and one or more associated antennas mounted to reflector assembly 200. In some embodiments, one or more antennas are mounted to the external facing surface(s) of flange 202 to maximize communication efficiency between reflector assembly 200 and a remotely located communications device (e.g., router, mobile phone, or other computing system). Any suitable wireless communications protocol may be contemplated, (e.g., Bluetooth, 802.11, Zigbee, etc.).
The flange 202′ is not in the direct optical path of light emitted from LED based illumination device 100. The surface profiles of reflective surfaces 201A and 201B are selected to promote uniform light output from luminaire 150 in spite of the optical discontinuity in the reflector introduced by flange 202′.
In some embodiments, the reflector (including reflective surfaces 201A and 201B and flange 202′ is manufactured as one part by a molding process. However, in some other embodiments, the shapes of reflective surfaces 201A and 201B may cause the molding of the reflector to be prohibitively difficult. In such embodiments, it is desirable to construct the reflector by combining multiple parts. For example two molded parts may be joined (e.g., by chemical bonding, friction bonding, welding, etc.).
In yet another aspect, the reflector of reflector assembly 200′″ is detachably coupled to reflector housing 210. As depicted in
In some embodiments, reflector interface module 203 includes a Power Line Communication (PLC) module operable to receive a electrical power signal and decode a communication signal from the electrical power signal (e.g., signals 211).
In a further aspect, reflector interface module 203 includes a memory that can be employed to store identification data, operational data, etc. For example, an identification number, a network security key, commissioning information, etc. may be stored on the memory.
In another further aspect, reflector interface module 203 includes a processor and processor readable instructions stored on the memory that cause the processor to receive a control signal on a first input node of the reflector interface module 203, determine a desired luminous output of the LED based illumination device based on the control signal, and transmit a command signal to the direct current to direct current (DC/DC) power converter electrically coupled to the LED based illumination device to change the luminous output of the LED based illumination device. In this manner, a processor on board the reflector interface module 203 provides control over the light emitted from the luminaire 150.
In some embodiments, the control signal the control signal adheres to any of a Digital Addressable Lighting Interface (DALI) standard, a DMX standard, and a 0-10 Volt standard.
In some embodiments, the command signal is based on a sensor signal received from a sensor 204 coupled to the reflector housing.
In another aspect, a top facing heat sink is detachably coupled to the LED based illumination device, wherein the reflector interface module is disposed between the top facing heat sink and the reflector.
Reflector 201 may also be made from thermally conductive material and may be thermally coupled to any of illumination device 100 and top facing heat sink 130. In these embodiments, heat flows by conduction into thermally conductive reflector 201 and is dissipated into the environment. Heat also flows via thermal convection over the reflector 201. Optical elements, such as a diffuser or reflector may be detachably coupled to illumination device 100, e.g., by means of threads, a clamp, a twist-lock mechanism, or other appropriate arrangement.
The top facing heat sink 130 and reflector 201 are detachably coupled to illumination device 100. For example, any of top facing heat sink 130 and reflector 201 may be coupled to illumination device 100 by a twist-lock mechanism. In this manner any of top facing heat sink 130 and reflector 201 is aligned with illumination device 100 and is coupled to illumination device 100 by rotating any of top facing heat sink 130 and reflector 201 about an optical axis (OA) of luminaire 150. In the engaged position, an interface pressure is generated between mating thermal interface surfaces of any of top facing heat sink 130 and reflector 201 and illumination device 100. In this manner, heat generated by LEDs of the LED based illumination device is dissipated into any of top facing heat sink 130 and reflector 201.
In some embodiments, luminaire 150 includes an reflector interface module 203′ within an envelope formed by top facing heat sink 130. The reflector interface module 203′ communicates electrical signals to and from reflector assembly 200. In the embodiment depicted in
Although certain specific embodiments are described above for instructional purposes, the teachings of this patent document have general applicability and are not limited to the specific embodiments described above. Accordingly, various modifications, adaptations, and combinations of various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the claims.
This application claims priority under 35 USC 119 to U.S. Provisional Application No. 61/988,668, filed May 5, 2014, which is incorporated by reference herein in its entirety.
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