Polarized, led-based illumination source
First Claim
1. A method of manufacturing an illumination source, comprising:
- providing one or more (LED) dies having a metallic layer on respective LED lower surfaces,placing the LED dies in thermal contact with a first surface of a plate whose temperature is controllable by flowing a fluid past a second surface of the metal plate;
passing a heated fluid by the second surface of the plate so as to melt the metallic layer; and
cooling the metallic layer so that the metallic layer solidifies, thereby attaching the LED dies to the first surface of the liquid cooled plate.
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Abstract
An illumination source includes a number of light emitting diodes (LEDs) operating at a first wavelength. Light from the LEDs illuminates a phosphor material that generates light at a second wavelength. A reflective polarizer transmits light at the second wavelength in a first polarization state and reflects light at the second wavelength in a second polarization state orthogonal to the first polarization state. The light at the second wavelength reflected by the reflective polarizer is directed back towards the phosphor material without an increase in angular range. In some embodiments the LEDs, having a conformal layer of phosphor material, are attached directly to the first surface of a liquid cooled plate. A liquid coolant contacts a second surface of the plate.
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Citations
13 Claims
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1. A method of manufacturing an illumination source, comprising:
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providing one or more (LED) dies having a metallic layer on respective LED lower surfaces, placing the LED dies in thermal contact with a first surface of a plate whose temperature is controllable by flowing a fluid past a second surface of the metal plate; passing a heated fluid by the second surface of the plate so as to melt the metallic layer; and cooling the metallic layer so that the metallic layer solidifies, thereby attaching the LED dies to the first surface of the liquid cooled plate. - View Dependent Claims (2, 3, 4, 5)
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6. An illumination system comprising:
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a light source capable of emitting light at a first and a second wavelength and comprising; an array of one or more light emitting diode (LED) dies, each LED die being capable of generating light at the first wavelength and being coated with a phosphor material, the phosphor material generating light at the second wavelength when illuminated by light at the first wavelength; and a heat sink capable of being cooled with a coolant, the heat sink having a first surface and a second surface, the array of one or more LED dies being mounted on the first surface of the heat sink, a metal coating providing attachment between each LED die and the heat sink; a light pipe disposed to receive light emitted by the light source; a first reflective element for transmitting light at the second wavelength generated by the phosphor material and reflecting light at the first wavelength emitted by the array of one or more light emitting diode (LED) dies for recycling to the phosphor material; and a polarizing beam splitter for transmitting light at the second wavelength in a first polarization state and reflecting light at the second wavelength in a second polarization state orthogonal to the first polarization state for conversion to the first polarization state. - View Dependent Claims (7, 8, 9, 10, 11, 12, 13)
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Specification