1. Field
The present disclosure relates to light sources, and more particularly to light sources using optics to produce substantially spherical emission patterns.
2. Background
Solid state devices, such as light emitting diodes (LED)s, are attractive candidates for replacing conventional light sources such as incandescent, halogen and fluorescent lamps. LEDs have substantially higher light conversion efficiencies than incandescent and halogen lamps and longer lifetimes than all three of these types of conventional light sources. In addition, some types of LEDs now have higher conversion efficiencies than fluorescent light sources and still higher conversion efficiencies have been demonstrated in the laboratory. Finally, LEDs require lower voltages than fluorescent lamps and contain no mercury or other potentially dangerous materials, therefore, providing various safety and environmental benefits.
The typical LED has a lambertian emission pattern. This means that light emitted from the LED typically spans a hemispherical arc. This emission pattern may limit the use of LED light sources, or other solid state lighting devices, as replacements for conventional light sources for incandescent, halogen and fluorescent lamps, which emit light in all directions. An LED light source that is used in an incandescent light bulb, for example, may result in undesired dark spots in the downward direction. In common lighting applications, such as desk, floor, and table lamps, this can result in no downward light to enable work or reading tasks.
Accordingly, there is a need in the art for a solid state light source that has an emission pattern that better resembles conventional incandescent, halogen and fluorescent lamps.
In one aspect of the disclosure, a light source includes a substrate, a plurality of solid state light emitting cells having a planar arrangement on the substrate, and one or more reflectors arranged with the solid state light emitting cells so that light emitted from the light source has a substantially spherical emission pattern.
In another aspect of the disclosure, a light source includes a substrate, a plurality of solid state light emitting cells arranged on the substrate to emit light in substantially the same direction, and one or more reflectors arranged with the solid state light emitting cells so that the light is emitted from the light source with a substantially spherical emission pattern.
In yet another aspect of the disclosure, a light source includes a substrate, a plurality of solid state light emitting cells having a substantially planar arrangement on the substrate, and means for reflecting light emitted from the solid state light emitting cells so that the light is emitted from the light source with a substantially spherical emission pattern.
In a further aspect of the disclosure, a lamp includes a housing having a base and a transparent bulb portion mounted to the base, and a light source within the housing. The light source includes a substrate, plurality of solid state light emitting cells having a substantially planar arrangement on the substrate, and one or more reflectors arranged with the solid state light emitting cells so that light emitted from the transparent bulb portion has a substantially spherical emission pattern.
It is understood that other aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only exemplary configurations of a light source by way of illustration. As will be realized, the present invention includes other and different aspects of a light source and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and the detailed description are to be regarded as illustrative in nature and not as restrictive.
Various aspects of the present invention are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein:
The present invention is described more fully hereinafter with reference to the accompanying drawings, in which various aspects of the present invention are shown. This invention, however, may be embodied in many different forms and should not be construed as limited to the various aspects of the present invention presented throughout this disclosure. Rather, these aspects are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. The various aspects of the present invention illustrated in the drawings may not be drawn to scale. Rather, the dimensions of the various features may be expanded or reduced for clarity. In addition, some of the drawings may be simplified for clarity. Thus, the drawings may not depict all of the components of a given apparatus or method.
Various aspects of the present invention will be described herein with reference to drawings that are schematic illustrations of idealized configurations of the present invention. As such, variations from the shapes of the illustrations as a result, for example, manufacturing techniques and/or tolerances, are to be expected. Thus, the various aspects of the present invention presented throughout this disclosure should not be construed as limited to the particular shapes of elements (e.g., regions, layers, sections, substrates, etc.) illustrated and described herein but are to include deviations in shapes that result, for example, from manufacturing. By way of example, an element illustrated or described as a rectangle may have rounded or curved features and/or a gradient concentration at its edges rather than a discrete change from one element to another. Thus, the elements illustrated in the drawings are schematic in nature and their shapes are not intended to illustrate the precise shape of an element and are not intended to limit the scope of the present invention.
It will be understood that when an element such as a region, layer, section, substrate, or the like, is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. It will be further understood that when an element is referred to as being “formed” on another element, it can be grown, deposited, etched, attached, connected, coupled, or otherwise prepared or fabricated on the other element or an intervening element.
Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another element as illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations of an apparatus in addition to the orientation depicted in the drawings. By way of example, if an apparatus in the drawings is turned over, elements described as being on the “lower” side of other elements would then be oriented on the “upper” side of the other elements. The term “lower”, can therefore, encompass both an orientation of “lower” and “upper,” depending of the particular orientation of the apparatus. Similarly, if an apparatus in the drawing is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and this disclosure.
As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The term “and/or” includes any and all combinations of one or more of the associated listed items
Various aspects of a light source will now be presented. However, as those skilled in the art will readily appreciate, these aspects may be extended to other light sources without departing from the spirit and scope of the invention. The light source may include a substrate, a plurality of solid state light emitting cells having an arrangement on the substrate, and one or more reflectors arranged with the solid state light emitting cells so that light emitted from the light source has a substantially spherical emission pattern. The light source may be used as a direct replacement for conventional light sources currently being used in incandescent, fluorescent, halogen, quartz, high-density discharge (HID), and neon lamps, to name a few.
An example of a solid state light emitting cell is an LED. The LED is well known in the art, and therefore, will only briefly be discussed to provide a complete description of the invention.
Referring to
The electrodes 106 and 108 may be formed on the surface of the epitaxial-layer structure 104. The p-type semiconductor region 118 is exposed at the top surface, and therefore, the p-type electrode 106 may be readily formed thereon. However, the n-type semiconductor region 114 is buried beneath the p-type semiconductor region 118 and the active region 116. Accordingly, to form the n-type electrode 108 on the n-type semiconductor region 114, a portion of the active region 116 and the p-type semiconductor region 118 is removed to expose the n-type semiconductor region 114 therebeneath. After this portion of the epitaxial-layer structure 104 is removed, the n-type electrode 108 may be formed.
In one configuration of a light source, multiple LEDs, or other light emitting cells, may be used to provide increased luminance. The light source may be constructed in a 2-dimensional planar fashion, or some other fashion. One example of a light source will now be presented with reference to
The light source may be configured to produce white light. White light may enable the light source to act as a direct replacement for conventional light sources used today in incandescent, halogen and fluorescent lamps. There are at least two common ways for producing white light. One way is to use individual LEDs that emit discrete wavelengths (such as red, green, blue, amber or other colors) and then mix all the colors to produce white light. The other way is to use a phosphor material or materials to convert monochromatic light emitted from a blue or ultra-violet (UV) LED to broad-spectrum white light. The present invention, however, may be practiced with other LED and phosphor combinations to produce different color lights.
An example of a white light source will now be presented with reference to
In an alternative configuration of a white light source, each LED may have its own phosphor layer. As those skilled in the art will readily appreciate, various configurations of LEDs and other light emitting cells may be used to create a white light source. Moreover, as noted earlier, the present invention is not limited to solid state lighting devices that produce white light, but may be extended to solid state lighting devices that produce other colors of light.
The light source may also be configured with one or more reflectors arranged with the LEDs so that light emitted from the light source has a substantially spherical emission pattern. An example will now be presented with reference to
The emission pattern may be changed by varying any number of parameters. These parameters include the number and the positional arrangement of the LEDs 401 on the substrate 402, and the length and the inclination of the reflector 404 extending over the LEDs 401. By way of example, more light may be directed upwards by shortening the length of the reflectors 404, thereby exposing more of the LEDs 401. In contrast, more light may be directed downwards by increasing the length of the reflectors 404. These parameters may be varied to optimize the uniform distribution of light in applications where the light source is intended to be used as a replacement light source in conventional incandescent, halogen and fluorescent lamps. Alternatively, these parameters may be varied to direct more light downwards as may be required in the case of a desk, table, floor or reading lamp or other similar applications. Those skilled in the art will readily be to determine how best to vary these parameters for any particular lighting application based on the teachings presented throughout this disclosure.
Those skilled in the art will also recognize various configurations that may be used to produce a light source with a spherical, or otherwise desirable, emission pattern. By way of example, the length of one or more of the reflectors 404 may be different. Alternatively, or in addition to, one or more reflectors 404 may be used to partially or completely extend over some of the LEDs 401, while allowing the other LEDs 401 to exhibit a lambertian emission pattern unobstructed by any of the reflectors 404. The optical configuration used to produce a substantially spherical emission pattern may include multiple reflectors, as shown and described above, or alternatively, a single reflector that extends circumferentially along the entire inner edge of the substrate and is cantilevered to form a lip that extends partially over all the LEDs 401.
The reflector 404 may be fabricated by any means known in the art, now known or later developed. By way of example, the reflector 404 may include a plastic substrate with a reflective surface coated on the inside portion of the reflector 404. The plastic or other substrate material may be have a roughened surface or may be formed with multiple dimples so that the coated reflective surface scatters the reflected light emitted from the LED. The one or more reflectors 404 may be integrated with the substrate 402 and formed with a suitable mold, or alternatively, formed separately from the substrate 402 and attached to the substrate 402 using an adhesive or other suitable means.
As noted earlier, a light source that produces a substantially spherical emission pattern from solid state light emitting cells is well suited to function as a replacement light source in conventional incandescent, halogen and fluorescent lamps. An exampled will now be presented with reference to
A light source 500 may be positioned within the housing 512. The light source 500 may take on various forms, including by way of example, the configuration presented earlier in connection with
A plate 522 anchored to the base 516 provides support for the light source 500. In one configuration of a lamp 510, standoffs 524 extending from the plate 522 are used to separate the light source 500 from the plate 522. The plate 522 may be constructed from any suitable insulting material, including by way of example, glass. In the case of glass, the transparent bulb portion 514 of the housing 512 can be fused to the plate 522 to seal the light source 500.
A fan 526 may be used to cool the light source 500. The fan 526 may be an electronic fan or some other suitable device that generates airflow to cool the light source 500. An electronic fan is a device that generally exploits the concept of corona wind. Corona wind is a physical phenomenon that is produced by a strong electric field. These strong electric fields are often found at the tips of electrical conductors where electric charges, which reside entirely on the surface of the conductor, tend to accumulate. When the electric field reaches a certain strength, known as the corona discharge inception voltage gradient, the surrounding air is ionized with the same polarity as the tip of the conductor. The tip then repels the ionized air molecules surrounding it, thereby creating airflow. A non-limiting example of an electronic fan that exploits corona wind to generate airflow is an RSD5 solid-state fan developed by Ventiva or Thorrn Micro Technologies, Inc. The fan 526 may be mounted to the light source 500 as shown in
Alternatively, heat pipes may be used to both support the light source 500 above the plate 522 and to dissipate heat away from the light source 500. In connection with the latter function, the heat pipes may be used in conjunction with, or instead of, the fan 526. The heat pipes may extend through a stack of spaced apart thermally conductive plates in the base 516, which function to dissipate heat away from the heat pipes through multiple vents in the base 516.
The plate 522 also provides a means for routing wires 528a and 528b from the light source 500 to electrical contacts 530a and 530b on the base 516. In one configuration of a lamp 510, the standoffs 524 previously described may be hollow, and the wires 530a and 530b may be routed from the plate 522 to the light source 500 through the hollow standoffs 524. In another configuration of a lamp 510, the wires 528a and 528b themselves can be used to separate the light source 500 from the plate 522, thus eliminating the need for standoffs 524. In the latter configuration, the wires 528a and 528b may be spot welded to feedthrough holes in the plate 522 with another set of spot welded wires extending from the feedthrough holes to the electrical contacts 530a and 530b on the base 516.
The arrangement of electrical contacts 530a and 530b and physical shape of the connecting lamp base may vary depending on the particular application. By way of example, the lamp 510 may have a base 516 with a screw cap configuration, as shown in
Power may be applied to the light source 500 and the fan 526 through the electrical contacts 530a and 530b. An AC-DC converter (not shown) may be used to generate a DC voltage from a lamp socket connected to a wall-plug in a household, office building, or other facility. The DC voltage generated by the AC-DC converter may be provided to a driver circuit (not shown) configured to drive both the light source 500 and the fan 526. The AC-DC converter and the driver circuit may be located in the base 516, in the light source 500, or anywhere else in the housing 512. In some applications, the AC-DC converter may not be needed. By way of example, the light source 500 and the fan 526 may be designed for AC power. Alternatively, the power source may be DC, such as the case might be in automotive applications. The particular design of the power delivery circuit for any particular application is well within the capabilities of one skilled in the art.
As discussed in greater detail earlier, a white light source may be constructed from a substrate carrying multiple blue or UV LEDs and a phosphor material to produce a white light source. Alternatively, the phosphor material may be formed on the inner surface of transparent bulb portion 514 of the housing 512 to produce a white light source. In another configuration of a lamp, a white light source may be produced by embedding the phosphor material in the transparent bulb portion 514 of the housing 512. These concepts are more fully described in U.S. patent application Ser. No. 12/360,781, entitled “Phosphor Housing for Light Emitting diode Lamp,” the contents of which is incorporated by reference as though fully set forth herein.
The various aspects of this disclosure are provided to enable one of ordinary skill in the art to practice the present invention. Various modifications to aspects presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be extended to other lamp configurations regardless of the shape or diameter of the glass enclosure and the base and the arrangement of electrical contacts on the lamp. By way of example, these concepts may be applied to bulb shapes commonly referred to in the art as A series, B series, C-7/F series, ER, G series, GT, K, P-25/PS-35 series, BR series, MR series, AR series, R series, RP-11/S series, PAR Series, Linear series, and T series; ED17, ET, ET-18, ET23.5, E-25, BT-28, BT-37, BT-56. These concepts may also be applied to base sizes commonly referred to in the art as miniature candela screw base E10 and E11, candela screw base E12, intermediate candela screw base E17, medium screw base E26, E26D, E27 and E27D, mogul screw base E39, mogul Pf P40s, medium skirt E26/50×39, candela DC bay, candela SC bay B15, BA15D, BA15S, D.C. Bayonet, 2-lug sleeve B22d, 3-lug sleeve B22-3, medium Pf P28s, mogul bi-post G38, base RSC, screw terminal, disc base, single contact, medium bi-post, mogul end prong, spade connector, mogul pre-focus and external mogul end prong; admedium skirted, medium skirted, position-oriented mogul, BY 22 D, Fc2, ceramic spade series (J, G, R), RRSC, RSC; single pin series, bi-pin series, G, GX, 2G series. Thus, the claims are not intended to be limited to the various aspects of this disclosure, but are to be accorded the full scope consistent with the language of the claims. All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”
Pursuant to 35 U.S.C. §119(e), this application claims the benefit of U.S. Provisional Application Ser. No. 61/183,437 filed on Jun. 2, 2009, the contents of which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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61183437 | Jun 2009 | US |