Incandescent lamp incorporating extended high-reflectivity IR coating and lighting fixture incorporating such an incandescent lamp

• US 20060226777A1
• Filed: 03/24/2006
• Published: 10/12/2006
• Est. Priority Date: 04/07/2005
• Status: Abandoned Application

• Current Assignee: David W. Cunningham
• Original Assignee: David W. Cunningham
• Inventors: Cunningham, David W.
• Application Number:
  US11/388,770
• Publication Number:
  US 20060226777A1
• Time in Patent Office: Days
• US Class Current: 313/580
• CPC Class Codes: C03C 17/005 Coating the outside
• CPC Class Codes: C03C 17/3417 all coatings being oxide coatings
• CPC Class Codes: F21V 7/28 characterised by coatings
• CPC Class Codes: G02B 5/282 reflecting for infrared and transparent for visible light, e.g. heat reflectors, laser protection
• CPC Class Codes: H01K 1/325 Reflecting coating
• CPC Class Codes: H01K 3/005 Methods for coating the surface of the envelope

Abstract

An incandescent lamp is disclosed, incorporating a special optical coating system that enables the lamp to provide an improved luminous efficacy. In one form, the optical coating system includes a plurality of dielectric layers having prescribed refractive indices and prescribed thicknesses, which are selected such that the optical coating provides a prescribed transmittance/reflectance spectrum having an average reflectance greater than 90% across an infrared wavelength range of 740 to 2000 nm and further having an average transmittance of less than 90% across a visible wavelength range of 400 to 700 nm. In another form, the optical coating system includes two distinct coatings: (1) a first coating including a plurality of dielectric layers having prescribed refractive indices and prescribed thicknesses, which are selected such that the first coating provides a prescribed transmittance/reflectance spectrum, and (2) a second coating including a transparent electrically conductive material configured such that the second coating provides a prescribed transmittance/reflectance spectrum. The invention also is embodied in a lighting fixture incorporating an optical coating as described above, located either on the envelope of the incandescent lamp, itself, or on another substrate of the fixture, separate and apart from the lamp, e.g., a fixed transparent envelope surrounding the incandescent lamp.

Claims

1. An incandescent lamp comprising:

a filament;

a transparent envelope defining an enclosed space in which the filament is located; and

an optical coating disposed on a surface of the envelope, for transmitting light emitted by the filament in a prescribed visible wavelength band, while reflecting back toward the filament light emitted by the filament in other wavelength bands, whereupon a portion of such reflected light is absorbed by the filament;

wherein the optical coating includes a plurality of dielectric layers having prescribed refractive indices and prescribed thicknesses, which are selected such that the optical coating provides a prescribed transmittance/reflectance spectrum having an average reflectance greater than 90% across an infrared wavelength range of 740 to 2000 nm and further having an average transmittance of less than 90% across a visible wavelength range of 400 to 700 nm;

and wherein the optical coating cooperates with the filament such that the lamp provides a higher luminous efficacy than would a corresponding lamp lacking such an optical coating.

2. An incandescent lamp as defined in claim 1, wherein the optical coating is configured such that the lamp has a luminous efficacy of at least 40 lumens per watt.

3. An incandescent lamp as defined in claim 1, wherein the optical coating is configured such that the lamp has a luminous efficacy of at least 60 lumens per watt.

4. An incandescent lamp as defined in claim 1, wherein the optical coating is configured such that the lamp has a luminous efficacy of at least 80 lumens per watt.

5. An incandescent lamp as defined in claim 1, wherein the optical coating is located on the outer surface of the transparent envelope.

6. An incandescent lamp as defined in claim 1, wherein the refractive indices and thicknesses of the dielectric layers of the optical coating are selected such that the optical coating provides a transmittance/reflectance spectrum having an average reflectance greater than 95% across an infrared wavelength range of 740 to 2000 nm.

7. An incandescent lamp as defined in claim 1, wherein:

the optical coating includes a stack of alternating layers of high- and low-refractive index materials;

the high-refractive index layers all incorporate a material selected from the group consisting of TiO₂, Ta₂O₅, NbO₂, and mixtures thereof, and

the low-refractive index layers all incorporate a material selected from the group consisting of SiO₂, Al₂O₃, and mixtures thereof.

8. An incandescent lamp as defined in claim 1, wherein the optical coating further includes one or more transparent electrically conductive layers.

9. An incandescent lamp as defined in claim 8, wherein the one or more transparent electrically conductive layers are contiguous with the plurality of dielectric layers.

10. An incandescent lamp as defined in claim 8, wherein the one or more transparent electrically conductive layers are configured to have an average reflectance greater than 70% across an infrared wavelength range of 2000 to 4000 nm.

11. An incandescent lamp as defined in claim 1, and further comprising:

an electrical connector to which the transparent envelope is secured; and

a reflective coating disposed on a portion of the transparent envelope adjacent to the electrical connector, for reflecting visible and infrared light back toward the filament.

40. An incandescent lamp as defined in claim 8, wherein:

the optical coating further includes an IR-emissive coating located on the side of the one or more transparent electrically conductive layers opposite the filament; and

the IR-emissive coating has an average outer IR emissivity greater than that of a corresponding incandescent lamp lacking such an IR-emissive coating.

41. An incandescent lamp as defined in claim 40, wherein the optical coating further includes an oxygen diffusion barrier located between the one or more transparent electrically conductive layers and the IR-emissive coating.

42. An incandescent lamp as defined in claim 8, wherein:

the optical coating further includes an IR-emissive coating located on the side of the one or more transparent electrically conductive layers opposite the filament; and

the IR-emissive coating has a peak emissivity at a wavelength corresponding to the peak emission wavelength of the lamp envelope when the lamp is operating at its maximum power level.

43. An incandescent lamp as defined in claim 42, wherein:

the IR-emissive coating includes indium tin oxide; and

the IR-emissive coating has a plasma frequency corresponding to the peak emission frequency of the lamp envelope when the lamp is operating at its maximum power level.

12. A lighting fixture comprising:

a housing;

a lamp socket carried by the housing; and

an incandescent lamp comprising

an electrical connector configured to be removably secured to the lamp socket,

a filament,

a transparent envelope secured to the electrical connector and defining an enclosed space in which the filament is located, and

an optical coating disposed on a surface of the envelope, for transmitting light emitted by the lamp filament in a prescribed visible wavelength band, while reflecting back toward the filament light emitted by the filament in other wavelength bands, whereupon a portion of such reflected light is absorbed by the filament;

wherein the optical coating includes a plurality of dielectric layers having prescribed refractive indices and prescribed thicknesses, which are selected such that the optical coating provides a prescribed transmission/reflection spectrum having an average reflectance greater than 90% across an infrared wavelength range of 740 to 2000 nm and further having an average transmittance of less than 90% across a visible wavelength range of 400 to 700 nm;

and wherein the optical coating cooperates with the filament such that the lighting fixture provides a higher luminous efficacy than would a corresponding lighting fixture lacking such an optical coating.

13. A lighting fixture comprising:

a housing;

a lamp socket carried by the housing; and

an incandescent lamp comprising

an electrical connector configured to be removably secured to the lamp socket,

a filament, and

a transparent envelope secured to the electrical connector and defining an enclosed space in which the filament is located;

wherein the lighting fixture further comprises an optical coating for transmitting light emitted by the lamp filament in a prescribed visible wavelength band, while reflecting back toward the filament light emitted by the filament in other wavelength bands, whereupon a portion of such reflected light is absorbed by the filament;

wherein the optical coating includes a plurality of dielectric layers having prescribed refractive indices and prescribed thicknesses, which are selected such that the optical coating provides a prescribed transmittance/reflectance spectrum having an average reflectance greater than 90% across an infrared wavelength range of 740 to 2000 nm and further having an average transmittance of less than 90% across a visible wavelength range of 400 to 700 nm;

and wherein the optical coating cooperates with the filament such that the lighting fixture provides a higher luminous efficacy than would a corresponding lighting fixture lacking such an optical coating.

14. A lighting fixture as defined in claim 13, wherein the optical coating is disposed on a surface of the transparent envelope of the incandescent lamp.

15. A lighting fixture as defined in claim 14, wherein the optical coating is disposed on the outer surface of the transparent envelope of the incandescent lamp.

16. A lighting fixture as defined in claim 13, wherein:

the lighting fixture further comprises a fixed transparent envelope surrounding the incandescent lamp; and

the optical coating is disposed on a surface of the fixed transparent envelope.

17. An incandescent lamp comprising:

a filament;

a transparent envelope defining an enclosed space in which the filament is located; and

an optical coating system disposed on a surface of the envelope, for transmitting light emitted by the filament in a prescribed visible wavelength band, while reflecting back toward the filament light emitted by the filament in other wavelength bands, whereupon a portion of such reflected light is absorbed by the filament;

wherein the optical coating system includes

a first coating including a plurality of dielectric layers having prescribed refractive indices and prescribed thicknesses, which are selected such that the first coating provides a prescribed transmittance/reflectance spectrum, and

a second coating including a transparent electrically conductive material having a thickness selected such that the second coating provides a prescribed transmittance/reflectance spectrum,

wherein the first and second coatings cooperate with each other and with the filament such that the lamp provides a higher luminous efficacy than would a corresponding lamp lacking such an optical coating system on its envelope.

18. An incandescent lamp as defined in claim 17, wherein the optical coating system is configured such that the lamp has a luminous efficacy of at least 40 lumens per watt.

19. An incandescent lamp as defined in claim 17, wherein the optical coating system is configured such that the lamp has a luminous efficacy of at least 60 lumens per watt.

20. An incandescent lamp as defined in claim 17, wherein the optical coating system is configured such that the lamp has a luminous efficacy of at least 80 lumens per watt.

21. An incandescent lamp as defined in claim 17, wherein the first and second coatings are contiguous with each other.

22. An incandescent lamp as defined in claim 21, wherein the optical coating system is located on the outer surface of the transparent envelope.

23. An incandescent lamp as defined in claim 21, wherein the second coating is located on the side of the first coating opposite the filament.

24. An incandescent lamp as defined in claim 21, wherein the second coating is located at an intermediate location within the plurality of layers of the first coating, closer to the side of the first coating opposite the filament than to the side of the first coating facing the filament.

25. An incandescent lamp as defined in claim 17, wherein:

the first coating includes a stack of alternating layers of high- and low-refractive index materials;

the high-refractive index layers all incorporate a material selected from the group consisting of TiO₂, Ta₂O₅, NbO₂, and mixtures thereof; and

the low-refractive index layers all incorporate a material selected from the group consisting of SiO₂, Al₂O₃, and mixtures thereof.

26. An incandescent lamp as defined in claim 17, wherein the second coating includes a transparent electrically conductive material selected from the group consisting of indium tin oxide, aluminum-doped zinc oxide, titanium-doped indium oxide, cadmium stannate, tin oxide-zinc stannate, gallium-doped zinc oxide, gold, silver, and mixtures thereof.

27. An incandescent lamp as defined in claim 17, wherein the first coating is configured such that it has an average reflectance greater than 90% across an infrared wavelength range of 740 to 2000 nm and such that it has an average transmittance less than 90% across a visible wavelength range of 400 to 700 nm.

28. An incandescent lamp as defined in claim 17, wherein the second coating is configured such that it has an average reflectance greater than 70% across an infrared wavelength range of 2000 to 4000 nm and such that it has an average absorptance less than 5% in the visible wavelength range of 400 to 700 nm.

29. An incandescent lamp as defined in claim 17, wherein the second coating is configured such that it has an average reflectance greater than 80% across an infrared wavelength range of 2000 to 4000 nm and such that it has an average absorptance less than 5% in the visible wavelength range of 400 to 700 nm.

30. An incandescent lamp as defined in claim 17, wherein the second coating is configured such that it has an average reflectance greater than 90% across an infrared wavelength range of 2000 to 4000 nm and such that it has an average absorptance less than 5% in the visible wavelength range of 400 to 700 nm.

31. An incandescent lamp as defined in claim 17, wherein the second coating is configured such that it has an average reflectance greater than 80% across an infrared wavelength range of 2000 to 4000 m and such that it has an average absorptance less than 10% in the visible wavelength range of 400 to 700 nm.

32. An incandescent lamp as defined in claim 17, wherein the second coating is configured such that it has an average reflectance greater than 90% across an infrared wavelength range of 2000 to 4000 nm and such that it has an average absorptance less than 10% in the visible wavelength range of 400 to 700 mm.

33. An incandescent lamp as defined in claim 17, wherein the second coating is configured such that it has an average reflectance greater than 90% across an infrared wavelength range of 2000 to 4000 nm and such that it has an average absorptance less than 20% in the visible wavelength range of 400 to 700 nm.

34. An incandescent lamp as defined in claim 17, and further comprising:

an electrical connector to which the transparent envelope is secured; and

a reflective coating disposed on a portion of the transparent envelope adjacent to the electrical connector, for reflecting visible and infrared light back toward the filament.

44. An incandescent lamp as defined in claim 23, wherein:

the optical coating system further includes an IR-emissive coating located on the side of the second coating opposite the filament; and

the IR-emissive coating has an average outer IR emissivity greater than that of a corresponding incandescent lamp lacking such an IR-emissive coating.

45. An incandescent lamp as defined in claim 44, wherein the optical coating system further includes an oxygen diffusion barrier located between the second coating and the IR-emissive coating.

46. An incandescent lamp as defined in claim 23, wherein:

the optical coating system further includes an IR-emissive coating located on the side of the second coating opposite the filament; and

the IR-emissive coating has a peak emissivity at a wavelength corresponding to the peak emission wavelength of the lamp envelope when the lamp is operating at its maximum power level.

47. An incandescent lamp as defined in claim 46, wherein:

the optical coating system includes indium tin oxide; and

the IR-emissive coating has a plasma frequency corresponding to the peak emission frequency of the lamp envelope when the lamp is operating at its maximum power level.

35. A lighting fixture comprising:

a housing;

a lamp socket carried by the housing; and

an incandescent lamp comprising

an electrical connector configured to be removably secured to the lamp socket,

a filament,

a transparent envelope secured to the electrical connector and defining an enclosed space in which the filament is located, and

an optical coating system disposed on a surface of the envelope, for transmitting light emitted by the lamp filament in a prescribed visible wavelength band, while reflecting back toward the filament light emitted by the filament in other wavelength bands, whereupon a portion of such reflected light is absorbed by the filament, wherein the optical coating system includes

a first coating including a plurality of dielectric layers having prescribed refractive indices and prescribed thicknesses, which are selected such that the first coating provides a prescribed transmittance/reflectance spectrum, and

a second coating including a transparent electrically conductive material having a thickness selected such that the second coating provides a prescribed transmittance/reflectance spectrum,

wherein the first and second coatings cooperate with each other

and with the filament such that the lamp provides a higher luminous efficacy than would a corresponding lamp lacking such an optical coating system on its envelope.

36. A lighting fixture comprising:

a housing;

a lamp socket carried by the housing; and

an incandescent lamp comprising

an electrical connector configured to be removably secured to the lamp socket,

a filament, and

a transparent envelope secured to the electrical connector and defining an enclosed space in which the filament is located,

wherein the fixture further comprises an optical coating system for transmitting light emitted by the filament in a prescribed visible wavelength band, while reflecting back toward the filament light emitted by the filament in other wavelength bands, whereupon a portion of such reflected light is absorbed by the filament;

and wherein the optical coating system includes

a first coating including a plurality of dielectric layers having prescribed refractive indices and prescribed thicknesses, which are selected such that the first coating provides a prescribed first transmission/reflection spectrum, and

a second coating including a transparent electrically conductive material having a thickness selected such that the second coating provides a prescribed second transmission/reflection spectrum,

wherein the first and second coatings cooperate with each other and with the filament such that the lighting fixture provides a higher luminous efficacy than would a corresponding lighting fixture lacking such an optical coating system.

37. A lighting fixture as defined in claim 36, wherein the optical coating system is disposed on a surface of the transparent envelope of the incandescent lamp.

38. A lighting fixture as defined in claim 37, wherein the optical coating system is disposed on the outer surface of the transparent envelope of the incandescent lamp.

39. A lighting fixture as defined in claim 36, wherein:

the lighting fixture further comprises a fixed transparent envelope surrounding the incandescent lamp; and

the optical coating is disposed on a surface of the fixed transparent envelope.