LED grow light system

• US 10,244,687 B1
• Filed: 02/28/2018
• Issued: 04/02/2019
• Est. Priority Date: 02/28/2018
• Status: Active Grant

• Current Assignee: SK Led, LLC (MVP Lightco Investco LLC)
• Original Assignee: Spectrum King LLC
• Inventors: Vardi, Rami
• Primary Examiner(s): Sawhney, Hargobind S
• Application Number:
  US15/908,539
• Time in Patent Office: 398 Days
• CPC Class Codes: A01G 7/045 with electric lighting
• CPC Class Codes: A01G 9/20 Forcing-frames; Lights , i.e. glass panels covering the forcing-frames
• CPC Class Codes: A01G 9/249 Lighting means with special arrangements for promoting growth A01G7/045
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 33/44 characterised by the coatings, e.g. passivation layer or anti-reflective coating
• CPC Class Codes: H01L 33/46 Reflective coating, e.g. dielectric Bragg reflector
• CPC Class Codes: H01L 33/50 Wavelength conversion elements
• CPC Class Codes: Y02P 60/14 Measures for saving energy, e.g. in green houses

Abstract

The LED grow light system includes an LED coupled to a circuit board, a phosphor layer generally positioned at least partially over the LED coupled to the circuit board, and a filter positioned in light receiving relation relative to the LED coupled to the circuit board and in light reflective relation relative to the phosphor layer. The filter includes a material at least partially reflective of at least a first light output wavelength emitted from the LED for redirection back into the phosphor layer where the reflected first light output wavelength converts to a second light output wavelength for recycled emission out from the LED grow light system as a composite light output component that includes a mixture of the first light output wavelength and the second light output wavelength.

Claims

1. An LED grow light system, comprising:

an LED coupled to a circuit board;

a phosphor layer generally positioned at least partially over the LED coupled to the circuit board;

a filter positioned in light receiving relation relative to the LED coupled to the circuit board and in light reflective relation relative to the phosphor layer, the filter comprising a material at least partially reflective of at least a first light output wavelength emitted from the LED for redirection back into the phosphor layer where the reflected first light output wavelength converts to a second light output wavelength for recycled emission out from the LED grow light system as a composite light output component comprising a mixture of the first light output wavelength and the second light output wavelength; and

an adhesive selectively securing the filter to the phosphor layer, wherein the filter comprises a filter substrate having a filter coating on an external surface area of the LED grow light system.

2. The LED grow light system of claim 1, wherein the second light output wavelength comprises a different wavelength than the first light output wavelength.

3. The LED grow light system of claim 1, wherein the first light output wavelength emitted from the LED grow light system as part of the composite light output component comprises an intensity relatively lower than the first light output wavelength emitted from the LED.

4. The LED grow light system of claim 1, wherein the second light output wavelength emitted from the LED grow light system as part of the composite light output component comprises an intensity relatively higher than the second light output wavelength emitted from the LED.

5. The LED grow light system of claim 1, wherein the LED comprises a blue LED and the first light output wavelength comprises a plurality of wavelengths within a blue spectra and the phosphor layer comprises a yellow phosphor and the second light output wavelength comprises a plurality of wavelengths in a yellow spectra.

6. The LED grow light system of claim 5, wherein the blue spectra comprise wavelengths between about 420-480 nm and the yellow spectra comprise wavelengths between about 560-600 nm.

7. The LED grow light system of claim 1, wherein the filter substrate comprises a generally transparent material and the filter coating comprises the reflective material.

8. The LED grow light system of claim 1, wherein the filter coating comprises a surface area less than coextensive with the filter substrate.

9. The LED grow light system of claim 1, wherein the adhesive comprises a reflective transparent glue, the filter substrate reflects a different wavelength than the filter coating, and the filter substrate permits pass-through of a different wavelength than the filter coating.

10. The LED grow light system of claim 1, wherein the filter includes a surface area coextensive with the phosphor layer.

11. The LED grow light system of claim 1, wherein the filter is at least partially opaque and comprises a 90%-99% reflective rate.

12. The LED grow light system of claim 1, wherein the filter comprises a filter cup coupled to a vertical support and generally positioned above the LED in non-contact relation relative thereto and cooperates with the circuit board to encapsulate the LED therein.

13. The LED grow light system of claim 12, wherein the filter cup adhesively couples to the vertical support, and the vertical support adhesively couples to the circuit board.

14. The LED grow light system of claim 12, including a filter coating coupled to an interior surface of the filter cup.

15. The LED grow light system of claim 1, wherein the circuit board includes multiple of the LEDs coupled thereto and the filter comprises a filter substrate having a plurality of filter coatings thereon and generally discretely aligned with each of the multiple LEDs coupled with the circuit board.

16. The LED grow light system of claim 15, wherein at least two of the plurality of filter coatings comprise a different material composition.

17. The LED grow light system of claim 1, wherein the LED grow light system comprises a flat grow light or a domed grow light.

18. The LED grow light system of claim 17, including an adhesive disposed along an exterior arcuate curvature of the domed grow light and generally forming a horizontal platform for select adhesive coupling with the filter.

19. The LED grow light system of claim 1, including a plurality of discrete LED grow light systems coupled to the circuit board, each including LEDs that vary in color.

20. The LED grow light system of claim 19, including a controller regulating operation of each of the plurality of discrete LED grow light systems in real-time.

21. The LED grow light system of claim 1, wherein the LED comprises multiple LEDs comprising a yellow LED, a green LED, an orange LED, and/or a red LED.

22. The LED grow light system of claim 1, wherein the composite light output component includes a green spectrum intensity of 10%-40% at wavelengths of about 500-570 nm.

23. The LED grow light system of claim 1, wherein the composite light output component includes a yellow spectrum intensity of 60%-90% at wavelengths of about 570-600 nm.

24. The LED grow light system of claim 1, wherein the composite light output component includes a blue spectrum intensity of 0%-20% at wavelengths of about 420-480 nm.

25. The LED grow light system of claim 1, wherein the composite light output component includes an orange spectrum intensity of 55%-100% at wavelengths of about 600-620 nm.

26. The LED grow light system of claim 1, wherein the composite light output component includes a red spectrum intensity of 10%-50% at wavelengths of about 620-700 nm.

27. The LED grow light system of claim 1, wherein the composite light output component includes a deep red spectrum of 5%-20% intensity at wavelengths of about 700-780 nm.

28. An LED grow light system, comprising:

an LED coupled to a circuit board;

a phosphor layer generally positioned at least partially over the LED coupled to the circuit board; and

a filter positioned in light receiving relation relative to the LED coupled to the circuit board and in light reflective relation relative to the phosphor layer, the filter comprising a material at least partially reflective of at least a first light output wavelength emitted from the LED for redirection back into the phosphor layer where the reflected first light output wavelength converts to a second light output wavelength for recycled emission out from the LED grow light system as a composite light output component comprising a mixture of the first light output wavelength and the second light output wavelength, wherein the filter comprises a filter cup coupled to a vertical support, and coupled to the circuit board, and generally positioned above the LED in non-contact relation relative thereto and cooperates with the circuit board to encapsulate the LED therein.

29. The LED grow light system of claim 28, wherein the second light output wavelength comprises a different wavelength than the first light output wavelength.

30. The LED grow light system of claim 28, wherein the first light output wavelength emitted from the LED grow light system as part of the composite light output component comprises an intensity relatively lower than the first light output wavelength emitted from the LED.

31. The LED grow light system of claim 28, wherein the second light output wavelength emitted from the LED grow light system as part of the composite light output component comprises an intensity relatively higher than the second light output wavelength emitted from the LED.

32. The LED grow light system of claim 28, wherein the LED comprises a blue LED and the first light output wavelength comprises a plurality of wavelengths within a blue spectra and the phosphor layer comprises a yellow phosphor and the second light output wavelength comprises a plurality of wavelengths in a yellow spectra.

33. The LED grow light system of claim 32, wherein the blue spectra comprise wavelengths between about 420-480 nm and the yellow spectra comprise wavelengths between about 560-600 nm.

34. The LED grow light system of claim 28, including an adhesive selectively securing the filter to the phosphor layer, wherein the filter comprises a filter substrate having a filter coating on an external surface area opposite the adhesive, the filter substrate comprises a generally transparent material, and the filter coating comprises the reflective material.

35. The LED grow light system of claim 34, wherein the filter coating comprises a surface area less than coextensive with the filter substrate.

36. The LED grow light system of claim 34, wherein the adhesive comprises a reflective transparent glue, the filter substrate reflects a different wavelength than the filter coating, and the filter substrate permits pass-through of a different wavelength than the filter coating.

37. The LED grow light system of claim 28, wherein the filter includes a surface area coextensive with the phosphor layer.

38. The LED grow light system of claim 28, wherein the filter is at least partially opaque and comprises a 90%-99% reflective rate.

39. The LED grow light system of claim 28, wherein the filter cup adhesively couples to the vertical support, and the vertical support adhesively couples to the circuit board.

40. The LED grow light system of claim 28, including a filter coating coupled to an interior surface of the filter cup.

41. The LED grow light system of claim 28, wherein the circuit board includes multiple of the LEDs coupled thereto and the filter comprises a filter substrate having a plurality of filter coatings thereon and generally discretely aligned with each of the multiple LEDs coupled with the circuit board.

42. The LED grow light system of claim 41, wherein at least two of the plurality of filter coatings comprise a different material composition.

43. The LED grow light system of claim 28, wherein the LED grow light system comprises a flat grow light or a domed grow light.

44. The LED grow light system of claim 43, including an adhesive disposed along an exterior arcuate curvature of the domed grow light and generally forming a horizontal platform for select adhesive coupling with the filter.

45. The LED grow light system of claim 28, including a plurality of discrete LED grow light systems coupled to the circuit board, each including LEDs that vary in color.

46. The LED grow light system of claim 45, including a controller regulating operation of each of the plurality of discrete LED grow light systems in real-time.

47. The LED grow light system of claim 28, wherein the LED comprises multiple LEDs comprising a yellow LED, a green LED, an orange LED, and/or a red LED.

48. The LED grow light system of claim 28, wherein the composite light output component includes a green spectrum intensity of 10%-40% at wavelengths of about 500-570 nm.

49. The LED grow light system of claim 28, wherein the composite light output component includes a yellow spectrum intensity of 60%-90% at wavelengths of about 570-600 nm.

50. The LED grow light system of claim 28, wherein the composite light output component includes a blue spectrum intensity of 0%-20% at wavelengths of about 420-480 nm.

51. The LED grow light system of claim 28, wherein the composite light output component includes an orange spectrum intensity of 55%-100% at wavelengths of about 600-620 nm.

52. The LED grow light system of claim 28, wherein the composite light output component includes a red spectrum intensity of 10%-50% at wavelengths of about 620-700 nm.

53. The LED grow light system of claim 28, wherein the composite light output component includes a deep red spectrum of 5%-20% intensity at wavelengths of about 700-780 nm.

54. An LED grow light system, comprising:

multiple LEDs coupled to a circuit board;

a phosphor layer generally positioned at least partially over the multiple LEDs coupled to the circuit board; and

a filter comprising a filter substrate having a plurality of filter coatings thereon and generally discretely aligned with each of the multiple LEDs coupled with the circuit board, the filter positioned in light receiving relation relative to the multiple LEDs coupled to the circuit board and in light reflective relation relative to the phosphor layer, the filter comprising a material at least partially reflective of at least a first light output wavelength emitted from the multiple LEDs for redirection back into the phosphor layer where the reflected first light output wavelength converts to a second light output wavelength for recycled emission out from the LED grow light system as a composite light output component comprising a mixture of the first light output wavelength and the second light output wavelength.

55. The LED grow light system of claim 54, wherein the second light output wavelength comprises a different wavelength than the first light output wavelength.

56. The LED grow light system of claim 54, wherein the first light output wavelength emitted from the LED grow light system as part of the composite light output component comprises an intensity relatively lower than the first light output wavelength emitted from the LED.

57. The LED grow light system of claim 54, wherein the second light output wavelength emitted from the LED grow light system as part of the composite light output component comprises an intensity relatively higher than the second light output wavelength emitted from the LED.

58. The LED grow light system of claim 54, wherein the LED comprises a blue LED and the first light output wavelength comprises a plurality of wavelengths within a blue spectra and the phosphor layer comprises a yellow phosphor and the second light output wavelength comprises a plurality of wavelengths in a yellow spectra.

59. The LED grow light system of claim 58, wherein the blue spectra comprise wavelengths between about 420-480 nm and the yellow spectra comprise wavelengths between about 560-600 nm.

60. The LED grow light system of claim 54, including an adhesive selectively securing the filter to the phosphor layer, wherein the filter comprises a filter substrate having a filter coating on an external surface area opposite the adhesive, the filter substrate comprises a generally transparent material, and the filter coating comprises the reflective material.

61. The LED grow light system of claim 60, wherein the filter coating comprises a surface area less than coextensive with the filter substrate.

62. The LED grow light system of claim 60, wherein the adhesive comprises a reflective transparent glue, the filter substrate reflects a different wavelength than the filter coating, and the filter substrate permits pass-through of a different wavelength than the filter coating.

63. The LED grow light system of claim 54, wherein the filter includes a surface area coextensive with the phosphor layer.

64. The LED grow light system of claim 54, wherein the filter is at least partially opaque and comprises a 90%-99% reflective rate.

65. The LED grow light system of claim 54, wherein the filter comprises a filter cup coupled to a vertical support and generally positioned above the LED in non-contact relation relative thereto and cooperates with the circuit board to encapsulate the LED therein, the filter cup being adhesively coupled to the vertical support and the vertical support being adhesively coupled to the circuit board.

66. The LED grow light system of claim 65, including a filter coating coupled to an interior surface of the filter cup.

67. The LED grow light system of claim 54, wherein at least two of the plurality of filter coatings comprise a different material composition.

68. The LED grow light system of claim 54, wherein the LED grow light system comprises a flat grow light or a domed grow light.

69. The LED grow light system of claim 68, including an adhesive disposed along an exterior arcuate curvature of the domed grow light and generally forming a horizontal platform for select adhesive coupling with the filter.

70. The LED grow light system of claim 54, including a plurality of discrete LED grow light systems coupled to the circuit board, each including LEDs that vary in color.

71. The LED grow light system of claim 70, including a controller regulating operation of each of the plurality of discrete LED grow light systems in real-time.

72. The LED grow light system of claim 54, wherein the LED comprises multiple LEDs comprising a yellow LED, a green LED, an orange LED, and/or a red LED.

73. The LED grow light system of claim 54, wherein the composite light output component includes a green spectrum intensity of 10%-40% at wavelengths of about 500-570 nm.

74. The LED grow light system of claim 54, wherein the composite light output component includes a yellow spectrum intensity of 60%-90% at wavelengths of about 570-600 nm.

75. The LED grow light system of claim 54, wherein the composite light output component includes a blue spectrum intensity of 0%-20% at wavelengths of about 420-480 nm.

76. The LED grow light system of claim 54, wherein the composite light output component includes an orange spectrum intensity of 55%-100% at wavelengths of about 600-620 nm.

77. The LED grow light system of claim 54, wherein the composite light output component includes a red spectrum intensity of 10%-50% at wavelengths of about 620-700 nm.

78. The LED grow light system of claim 54, wherein the composite light output component includes a deep red spectrum of 5%-20% intensity at wavelengths of about 700-780 nm.

79. An LED grow light system having a domed grow light, comprising:

an LED coupled to a circuit board;

a phosphor layer generally positioned at least partially over the LED coupled to the circuit board;

a filter positioned in light receiving relation relative to the LED coupled to the circuit board and in light reflective relation relative to the phosphor layer, the filter comprising a material at least partially reflective of at least a first light output wavelength emitted from the LED for redirection back into the phosphor layer where the reflected first light output wavelength converts to a second light output wavelength for recycled emission out from the LED grow light system as a composite light output component comprising a mixture of the first light output wavelength and the second light output wavelength; and

an adhesive disposed along an exterior arcuate curvature of the domed grow light and generally forming a horizontal platform for select adhesive coupling with the filter.

80. The LED grow light system of claim 79, wherein the second light output wavelength comprises a different wavelength than the first light output wavelength.

81. The LED grow light system of claim 79, wherein the first light output wavelength emitted from the LED grow light system as part of the composite light output component comprises an intensity relatively lower than the first light output wavelength emitted from the LED.

82. The LED grow light system of claim 79, wherein the second light output wavelength emitted from the LED grow light system as part of the composite light output component comprises an intensity relatively higher than the second light output wavelength emitted from the LED.

83. The LED grow light system of claim 79, wherein the LED comprises a blue LED and the first light output wavelength comprises a plurality of wavelengths within a blue spectra and the phosphor layer comprises a yellow phosphor and the second light output wavelength comprises a plurality of wavelengths in a yellow spectra.

84. The LED grow light system of claim 83, wherein the blue spectra comprise wavelengths between about 420-480 nm and the yellow spectra comprise wavelengths between about 560-600 nm.

85. The LED grow light system of claim 79, including an adhesive selectively securing the filter to the phosphor layer, wherein the filter comprises a filter substrate having a filter coating on an external surface area opposite the adhesive, the filter substrate comprises a generally transparent material, and the filter coating comprises the reflective material.

86. The LED grow light system of claim 85, wherein the filter coating comprises a surface area less than coextensive with the filter substrate.

87. The LED grow light system of claim 85, wherein the adhesive comprises a reflective transparent glue, the filter substrate reflects a different wavelength than the filter coating, and the filter substrate permits pass-through of a different wavelength than the filter coating.

88. The LED grow light system of claim 79, wherein the filter includes a surface area coextensive with the phosphor layer.

89. The LED grow light system of claim 79, wherein the filter is at least partially opaque and comprises a 90%-99% reflective rate.

90. The LED grow light system of claim 79, wherein the filter comprises a filter cup coupled to a vertical support and generally positioned above the LED in non-contact relation relative thereto and cooperates with the circuit board to encapsulate the LED therein, the filter cup being adhesively coupled to the vertical support and the vertical support being adhesively coupled to the circuit board.

91. The LED grow light system of claim 90, including a filter coating coupled to an interior surface of the filter cup.

92. The LED grow light system of claim 79, wherein the circuit board includes multiple of the LEDs coupled thereto and the filter comprises a filter substrate having a plurality of filter coatings thereon, at least two of which comprise a different material composition, and generally discretely aligned with each of the multiple LEDs coupled with the circuit board.

93. The LED grow light system of claim 79, including a plurality of discrete LED grow light systems coupled to the circuit board, each including LEDs that vary in color.

94. The LED grow light system of claim 93, including a controller regulating operation of each of the plurality of discrete LED grow light systems in real-time.

95. The LED grow light system of claim 79, wherein the LED comprises multiple LEDs comprising a yellow LED, a green LED, an orange LED, and/or a red LED.

96. The LED grow light system of claim 79, wherein the composite light output component includes a green spectrum intensity of 10%-40% at wavelengths of about 500-570 nm.

97. The LED grow light system of claim 79, wherein the composite light output component includes a yellow spectrum intensity of 60%-90% at wavelengths of about 570-600 nm.

98. The LED grow light system of claim 79, wherein the composite light output component includes a blue spectrum intensity of 0%-20% at wavelengths of about 420-480 nm.

99. The LED grow light system of claim 79, wherein the composite light output component includes an orange spectrum intensity of 55%-100% at wavelengths of about 600-620 nm.

100. The LED grow light system of claim 79, wherein the composite light output component includes a red spectrum intensity of 10%-50% at wavelengths of about 620-700 nm.

101. The LED grow light system of claim 79, wherein the composite light output component includes a deep red spectrum of 5%-20% intensity at wavelengths of about 700-780 nm.