Large surface LED lighting device

• US 6,361,190 B1
• Filed: 06/25/1999
• Issued: 03/26/2002
• Est. Priority Date: 06/25/1999
• Status: Expired due to Fees

• Current Assignee: Kevin Mcdermott
• Original Assignee: Kevin Mcdermott
• Inventors: McDermott, Kevin
• Primary Examiner(s): O'Shea, Sandra
• Assistant Examiner(s): Ton, Anabel
• Application Number:
  US09/344,041
• Time in Patent Office: 1,005 Days
• Field of Search: 313/512, 313/114, 313/113, 362/310, 362/277, 362/307, 362/800, 362/298-300, 362/302, 362/255, 362/256, 257/98
• US Class Current: 362/310
• CPC Class Codes: F21V 17/04 the fastening being onto or by the light source
• CPC Class Codes: F21V 7/0066 specially adapted to cooperate with point like light sources; specially adapted to cooperate with light sources the shape of which is unspecified F21V7/16 - F21V7/30 take precedence
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 2224/32245 the item being metallic
• CPC Class Codes: H01L 2224/32257 the layer connector connecting to a bonding area disposed in a recess of the surface of the item
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 33/54 having a particular shape
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

An enlarged surface LED lighting device having an interior reflector disposed and configured to reflect the light emitted by a LED element to increase the divergence of the light and form an interior reflected light. The interior reflector is typically a surface of revolution about the pattern axis configured to reflect and bend the light away from the axis of the spatial radiation pattern of the emitted light. The interior reflector is also formed to Increase the transfer of heat away from the LED element. The interior reflector is usually disposed in close proximity to the LED element to maximize the percentage of emitted light it redirects. The lighting device additionally includes an exterior reflector also normally a surface of revolution about the pattern axis. The exterior reflector is disposed and configured to reflect the interior reflected light previously reflected by the interior reflector to form an exterior reflected light and usually to decrease the divergence of -the interior reflected light about the pattern axis. The emerging light as a result of the interior and exterior reflectors emerges from the lighting device from a large lighted area.

Claims

1. A LED lighting device comprising:

a LED element emitting a light;

an interior reflector having a surface forming a hollow, said interior reflector attached to said LED element with said hollow on a side of said surface opposite said LED element, said interior reflector disposed intersecting said light and reflecting said light; and

an exterior reflector attached to said interior reflector disposed intersecting and reflecting the light reflected by said interior reflector.

10. A lighting device according to any of claims 1 thru 9 wherein:

said interior reflector comprises a surface of revolution.

11. A lighting device according to any of claims 1 thru 9 wherein:

said exterior reflector comprises a surface of revolution.

12. A lighting device according to any of claims 1 thru 9 which further includes:

said interior reflector comprising a conical contour.

13. A lighting device according to any of claims 1 thru 9 which further includes:

said interior reflector comprising a curved contour.

14. A lighting device according to any of claims 1 thru 9 which further includes:

said interior reflector comprising a parabolic contour.

15. A lighting device according to any of claims 1 thru 9 which further includes:

said exterior reflector comprising a curved contour.

16. A lighting device according to any of claims 1 thru 9 which further includes:

said exterior reflector comprising a conical contour.

17. A lighting device according to any of claims 1 thru 9 which further includes:

said exterior reflector comprising a parabolic contour.

18. A lighting device according to any of claims 1 thru 9 which further includes:

said interior reflector is nonmetallic.

19. A lighting device according to any of claims 1 thru 9 which further includes:

said exterior reflector is nonmetallic.

20. A lighting device according to any of claims 1,2,4,5,6,7,8, and 9 which further comprises:

said LED element emitting a second light;

a cup reflector attached to said LED element disposed with said LED element between said interior reflector and said cup reflector, said cup reflector intersecting said second light and reflecting said second light;

said interior reflector additionally intersecting and reflecting the second light reflected by said cup reflector; and

said exterior reflector additionally intersecting and reflecting the second light reflected by said interior reflector.

21. A lighting device according to any of claims 1, 2, 3, 4, 7, 8 and 9 wherein:

said light comprises a spatial radiation pattern having a divergence about a pattern axis.

22. A lighting device according to any of claims 1,2,4,5,6,7,8 and 9 wherein:

said exterior reflector comprises a reflective area larger than a reflective area of said interior reflector.

23. A lighting device according to any of claims 1 thru 6 which further includes:

a light transmitting medium encapsulating said LED element and having a light refracting surface disposed between said interior reflector and said exterior reflector.

24. A lighting device according to any of claims 1 thru 6 wherein:

said interior reflector is formed of a light transmitting medium; and

said light transmitting medium encapsulates said LED element.

25. A lighting device according to any of claims 1 thru 6 wherein:

said interior reflector is formed of a light transmitting medium; and

said exterior reflector is formed of said light transmitting medium.

26. A lighting device according to any of claims 1 thru 6 which further includes:

an optical surface between said LED element and said interior reflector.

27. A lighting device according to any of claims 1 thru 6 wherein:

said interior reflector is a component of an optical element glued to a transparent medium; and

said transparent medium encapsulates said LED element.

2. A LED lighting device comprising:

a LED element emitting a light;

a cup reflector attached to said LED element disposed intersecting said light and reflecting said light;

an interior reflector attached to said LED element with said LED element between said cup reflector and said interior reflector, said interior reflector disposed intersecting the light reflected by said cup reflector and reflecting the light; and

an exterior reflector attached to said interior reflector disposed intersecting and reflecting the light reflected by said interior reflector.

3. A LED lighting device comprising:

a LED element emitting a light having a divergence;

an interior reflector attached to said LED element disposed intersecting said light, reflecting said light and increasing said divergence of said light;

an exterior reflector attached to said interior reflector disposed intersecting and reflecting the light reflected by said interior reflector; and

said exterior reflector at least partially encircling said interior reflector and having a reflective area larger than a reflective area of said interior reflector.

4. A LED lighting device comprising:

a LED element emitting a light having a divergence;

an interior reflector attached to said LED element disposed intersecting said light, reflecting said light and increasing said divergence of said light; and

an exterior reflector attached to said interior reflector disposed intersecting the light reflected by said interior reflector, reflecting the light and decreasing the divergence of the light.

5. A LED lighting device comprising:

a LED element emitting a light in a spatial radiation pattern having a divergence about a pattern axis;

an interior reflector attached to said LED element disposed intersecting said light, reflecting said light and increasing said divergence of said light about said pattern axis; and

an exterior reflector at least partially encircling said interior reflector and attached to said interior reflector disposed intersecting and reflecting the light reflected by said interior reflector.

6. A LED lighting device comprising:

a LED element emitting a light in a spatial radiation pattern having a divergence about a pattern axis;

an interior reflector attached to said LED element disposed intersecting said light, reflecting said light and increasing said divergence of said light about said pattern axis; and

an exterior reflector attached to said interior reflector; and

disposed intersecting and reflecting the light reflected by said interior reflector.

7. A LED lighting device comprising:

a LED element emitting a light;

said LED element encapsulated in a light transmitting medium;

an interior reflector comprising a surface of said light transmitting medium disposed intersecting and reflecting said light, said surface comprising a hollow on a side of said surface opposite said LED element; and

an exterior reflector attached to said interior reflector disposed intersecting and reflecting the light reflected by said interior reflector.

8. A LED lighting device comprising:

a LED element emitting a light;

said LED element encapsulated in a light transmitting medium;

an interior reflector comprising a surface of said light transmitting medium disposed intersecting and reflecting the light; and

an exterior reflector comprising a surface of said light transmitting medium disposed intersecting and reflecting the light reflected by said interior reflector.

9. A LED lighting device comprising:

a LED element emitting a light in a spatial radiation pattern having a divergence about a pattern axis;

a light transmitting medium encapsulating said LED element, said light transmitting medium having a refracting surface and an interior reflector surface;

an interior reflector comprising said interior reflector surface disposed intersecting said light and reflecting said light;

an exterior reflector attached to said interior reflector;

said refracting surface disposed between said interior reflector and said exterior reflector intersecting and refracting the light reflected by said interior reflector; and

said exterior reflector disposed intersecting and reflecting the light refracted by said refracting surface.

28. A LED lighting device comprising:

a plurality of interior lighting devices each comprising a LED element emitting a light, an interior reflector having a surface forming a hollow, said interior reflector attached to said LED element with said hollow on a side of said surface opposite said LED element, said interior reflector disposed intersecting said light and reflecting said light; and

an exterior reflector attached to said plurality of interior lighting devices disposed with a common portion of said exterior reflector intersecting and reflecting the light reflected by said interior reflector of each of said interior lighting devices.

29. A LED lighting device comprising:

a plurality of composite lighting devices each comprising a LED element emitting a light an interior reflector having a surface forming a hollow, said interior reflector attached to said LED element with said hollow on a side of said surface opposite said LED element, said interior reflector disposed intersecting said light and reflecting said light, an exterior reflector attached to said interior reflector disposed intersecting and reflecting the light reflected by said interior reflector forming an exterior reflected light; and

each of said composite lighting device attached with said exterior reflected light directed into a composite light direction.

30. A LED lighting device comprising

a LED element for emitting light along a pattern axis;

an interior reflector spaced forwardly of said LED element on said axis for bending light from said element away from said axis; and

an exterior reflector spaced from and encircling said interior reflector to reflect light received from said interior reflector.

31. A LED lighting device as set forth in claim 30 wherein said exterior reflector has a surface for reflecting light received from said interior reflector towards parallelism with said pattern axis.

32. A LED lighting device as set forth in claim 30 wherein said exterior reflector has a surface for reflecting light received from said interior reflector away from parallelism with said pattern axis to increase the divergence of the light reflected therefrom.

33. A LED lighting device as set forth in claim 30 which further comprises a resin body enclosing said LED element and having a contoured surface thereof forming said interior reflector.

34. A LED lighting device as set forth in claim 33 wherein said contoured surface of said resin body is a parabolic contour.

35. A LED lighting device as set forth in claim 33 wherein said resin body has an index of refraction between 1.47 and 1.49.

36. A LED lighting device as set forth in claim 33 wherein said contoured surface is roughened.

37. A LED lighting device as set forth in claim 33 wherein said contoured surface has a portion thereof of a convex curved shape.

38. A LED lighting device as set forth in claim 33 wherein said contoured surface is at least partially parabolic and said resin body has a conical peripheral wall.

39. A LED lighting device as set forth in claim 33 which further comprises a reflective coating on at least some of said contoured surface for reflecting light from said LED element to a peripheral wall of said resin body.

40. A LED lighting device as set forth in claim 30 which further comprises a cup reflector spaced rearwardly of said LED on said pattern axis on a side opposite said interior reflector for receiving and reflecting light from said LED element towards said contoured surface.

41. A LED lighting device as set forth in claim 33 wherein said resin body has an outer peripheral surface defining said exterior reflector.

42. A LED lighting device as set forth in claim 30 wherein said exterior reflector has a parabolic surface for receiving and reflecting light from said interior reflector.

43. A LED lighting device as set forth in claim 42 wherein said exterior reflector is a resin body and said parabolic surface has a metallic coating thereon.

44. A LED lighting device as set forth in claim 42 wherein said exterior reflector has a conical reflective surface.

45. A LED lighting device as set forth in claim 42 wherein conical reflective surface of said exterior reflector has an outside radius greater than the thickness thereof to provide a large lighted area relative to said thickness.

46. A LED lighting device as set forth in claim 30 wherein said exterior reflector has a reflective surface disposed perpendicularly of said pattern axis.

47. A LED lighting device as set forth in claim 30 wherein said interior reflector has a parabolic reflective surface facing said LED element to reflect light outwardly from said pattern axis to said exterior reflector.

48. A LED lighting device as set forth in claim 47 further comprising a resin body enclosing said LED element and having a spherical surface facing said parabolic reflective surface of said interior reflector.

49. A lamp comprising

a plurality of LED lighting devices, each said lighting device having a LED element for emitting light along a pattern axis and an interior reflector spaced forwardly of said LED element on said axis for bending light from said element away from said axis;

and

an exterior reflector spaced from and encircling said lighting devices to reflect light received from said interior reflector of each said lighting device.

50. A lamp as set forth in claim 49 wherein said exterior reflector has a surface for reflecting light received from said interior reflector towards parallelism with said pattern axis.

51. A lamp comprising

a plurality of LED lighting devices disposed in a common direction to form a high intensity composite light directed in said common direction, each said lighting device having a LED element for emitting light about a pattern axis approximately parallel to said common direction, an interior reflector spaced forwardly of said LED element on said axis for bending light from said element away from said axis, and an exterior reflector spaced from and encircling said lighting devices to reflect light received from said interior reflector of each said lighting device.

52. A LED lighting device comprising

a LED element disposed on an axis for emitting light therefrom;

a resin body enclosing said LED element and having an outer peripheral wall and a contoured surface at one end disposed coaxially of said axis, said body having an index of refraction and said surface being light reflective for reflecting light from said LED element off said contoured surface to and through said peripheral wall to create an enlarged lighted surface; and

a cup reflector on said axis and within said body on a side opposite said contoured surface for receiving and reflecting light from said LED element towards said contoured surface.

53. A LED lighting device as set forth in claim 52 wherein said index of refraction is between 1.47 and 1.49.

54. A LED lighting device as set forth in claim 52 wherein said contoured surface is roughened.

55. A LED lighting device as set forth in claim 52 wherein said contoured surface has a parabolic contour.

56. A LED lighting device as set forth in claim 52 wherein said contoured surface has a portion thereof of a convex curved shape.

57. A LED lighting device as set forth in claim 52 wherein said contoured surface is at least partially parabolic and said peripheral wall is conical.

58. A LED lighting device as set forth in claim 52 which further comprises a reflective coating on at least some of said surface for reflecting light from said LED element to said peripheral.

59. A LED lighting device comprising

a LED element disposed on an axis for emitting light therefrom;

and

a resin body enclosing said LED element and having an outer peripheral wall and a contoured surface at one end to encircle said axis, said body having an index of refraction exceeding 1.1 and said surface being light reflective for reflecting light from said LED element off said contoured surface in a diverging pattern from said axis to pass through said peripheral wall to create an enlarged lighted surface.

60. A LED lighting device comprising

a LED element disposed on an axis for emitting light therefrom;

and

a resin body enclosing said LED element and having a contoured surface at one end to encircle said axis, said body having an index of refraction exceeding 1.1 and said surface being light reflective for reflecting light from said LED element off said contoured surface in a diverging pattern from said axis.

61. A LED lighting device comprising

a LED element for emitting a light in a spatial radiation pattern about a pattern axis, said light having a divergence about said pattern axis;

and

a light transmitting medium encapsulating said LED element and having an exterior surface of conical contour within a hollow opening to form a reflector about said pattern axis for reflecting said light from said LED element with an increased divergence.

62. An LED element as set forth in claim 61 wherein said reflector is disposed to intersect said light from said LED to form an angle at least equal to a critical angle.

63. A LED lighting device comprising

a LED element for emitting a light in a spatial radiation pattern about a pattern axis, said light having a divergence about said pattern axis;

and

a light transmitting medium encapsulating said LED element and having an exterior surface of convex contour within a hollow opening to form a reflector about said pattern axis for bending said light from said LED element away from said pattern axis.

64. An LED element as set forth in claim 63 wherein said reflector is disposed to intersect said light from said LED to form an angle at least equal to a critical angle.

65. A LED lighting device comprising

a LED element for emitting a light in a spatial radiation pattern about a pattern axis, said light having a divergence about said pattern axis;

and

a light transmitting medium encapsulating said LED element and having an exterior surface within a hollow opening to form a reflector about said pattern axis for intersecting and reflecting said light from said LED element with an increased divergence.

66. An LED element as set forth in claim 65 wherein said reflector is disposed to intersect said light from said LED to form an angle at least equal to a critical angle.