Collimating and controlling light produced by light emitting diodes

• US 8,469,542 B2
• Filed: 01/16/2008
• Issued: 06/25/2013
• Est. Priority Date: 05/18/2004
• Status: Expired due to Fees

• Current Assignee: Mark A. Zampini, Thomas L. Zampini, Thomas L. Zampini II
• Original Assignee: Thomas L. Zampini II
• Inventors: Zampini, Thomas L. II, Zampini, Mark A., Zampini, Thomas L.
• Primary Examiner(s): Makiya, David J
• Application Number:
  US12/015,376
• Publication Number:
  US 20080174997A1
• Time in Patent Office: 1,987 Days
• Field of Search: 362/555, 362/217.02, 362/227, 362/231, 362/244, 362/245, 36224901-24902
• US Class Current: 362/231
• CPC Class Codes: B29D 11/00663 Production of light guides
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction

Abstract

A light source channel is described. The light source channel includes an extrusion forming a channel having an open length and a light source positioned within the channel. A light transfer medium is positioned above the light source and covers the open length of the channel. The light transfer medium has a cross section. A method embodiment according to the present invention produces a light source channel by installing a light engine within a channel of an extrusion and covering the channel length with a light transfer medium above the light engine. The light transfer medium has a cross-section.

Claims

1. A system for collimating light emitted from a plurality of light source dies traversing a light transfer medium and averaging color temperatures of portions of the light emitted from the plurality of light source dies, the system comprising:

an extrusion forming a channel having an open length;

a drive system mounted on a circuit board inside the extrusion;

a plurality of light source dies positioned within the channel and mounted on the same circuit board as the drive system, wherein a first light source die of the plurality of light source dies emits a first light having a first color temperature different from a second color temperature of a second light emitted by a second light source die of the plurality of light source dies;

a light transfer medium positioned above the plurality of light source dies and covering at least a part of the open length of the extrusion, the light transfer medium having a bottom side and a rounded top side having a diameter;

wherein the height of the extrusion is configured to position the bottom side of the light transfer medium a predetermined distance of an air gap from a surface of each of the light source dies of the plurality of light source dies;

wherein the diameter of the rounded top side is configured in combination with the predetermined distance of the air gap between the surface of each of the light source dies and the light transfer medium to establish a particular emitting angle of a plurality of emitting angles of the first light and the second light traversing the light transfer medium; and

wherein the light transfer medium based on the diameter of the rounded top side and the distance of the air gap between the surface of each of the light source dies and the light transfer medium collects and collimates along a length of the light transfer medium covering the channel of the extrusion the first light and the second light within the emitting angle and average the first color temperature of a first portion of the first light with the second color temperature of a second portion of the second light.

2. The system of claim 1 wherein the channel further comprises a plurality of sides wherein at least one of the plurality of sides comprises a first reflective surface and wherein the first portion of the first light and the second portion of the second light reflect off the first reflective surface toward the bottom side of the light transfer medium.

3. The system of claim 2 further comprising a second reflective surface and wherein the first portion of the first light reflects off the first reflective surface toward the bottom side of the light transfer medium and the second portion of the second light reflects off the second reflective surface toward the bottom side of the light transfer medium.

4. The system of claim 2 wherein the distance of the air gap of the light transfer medium determines a range of collimation of the first portion of the first light and the second portion of the second light emanating through the light transfer medium.

5. The system of claim 1 wherein the extrusion provides a heat sink for the plurality of light source dies positioned within the channel.

6. The system of claim 1 wherein the extrusion provides an intermediary heat sink for an external heat sink.

7. The system of claim 1 wherein the light transfer medium covers the length of the extrusion and comprises a single optical cover for collimating the light emitted by each one of the plurality of light source dies.

8. The system of claim 1 wherein the channel further comprises one of a printed circuit board for controlling one or more of the plurality light source dies or a plurality of printed circuit boards for controlling the plurality of light source dies.

9. The system of claim 8 wherein the channel further comprises a drive system mounted inside the channel to eliminate one of wiring or an external driver for the printed circuit board.

10. The system of claim 1 further wherein the extrusion and the light transfer medium are potted with one of an epoxy or a sealant to provide waterproofing.

24. The system of claim 1, further comprising a reflector on an upper surface of the printed circuit board inside the extrusion, the reflector reflecting portions of the first light and the second light.

11. A method of collimating light emitted from a plurality of light source dies traversing a light transfer medium and averaging color temperatures of portions of the light emitted from the plurality of light source dies, the method comprising steps of:

providing, by a lighting system, an extrusion forming a channel having an open length, a drive system mounted on a circuit board inside the extrusion and housing a plurality of light source dies mounted on the same circuit board as the drive system, the lighting system comprising a light transfer medium having a bottom side and a rounded top side with a diameter, the height of the extrusion configured to position the bottom side of the light transfer medium a predetermined distance of an air gap from a surface of each of the light source dies of the plurality of light source dies housed by the extrusion;

emitting, by a first light source die of the plurality of light source dies, a first light having a first color temperature different from a second color temperature of a second light emitted by a second light source die of the plurality of light source dies;

collecting and collimating, by the light transfer medium along the length of the light transfer medium covering the channel of the extrusion the first light and the second light traversing the light transfer medium within a particular emitting angle of a plurality of emitting angles based on the combination of the configured diameter of the light transfer medium and the predetermined distance of the air gap; and

averaging, by the light transfer medium based on the diameter and the distance of the air gap, the first color temperature of a first portion of the first light with the second color temperature of a second portion of the second light.

12. The method of claim 11 further comprising reflecting, by a first reflective surface of a side of a plurality of sides comprised by the channel, the first portion of the first light emitted from the first light source and the second portion of the second light emitted from the second light source toward the bottom side of the light transfer medium.

13. The method of claim 12 wherein a second reflective surface of a plurality of sides comprised by the channel reflects the second portion of the second light from the second light source toward the bottom side of the light transfer medium.

14. The method of claim 12 further comprising diffusing, by the light transfer medium based on the distance of the air gap, the first portion of the first light and the second portion of the second light emanating through the light transfer medium.

15. The method of claim 11 wherein the extrusion provides a heat sink for the plurality of light source dies positioned within the channel.

16. The method of claim 11 wherein the extrusion provides an intermediary heat sink for an external heat sink.

17. The method of claim 11 further wherein light transfer medium covers the length of the extrusion and comprises a single optical cover for collimating the light emitted by each one of the plurality of light source dies.

18. The method of claim 11 wherein the lighting system comprises a printed circuit board inside the channel to control one of or more of the plurality of light source dies.

19. The method of claim 11 wherein the lighting system comprises a drive system mounted inside of the channel to provide one of a driver or a connection for the printed circuit board.

20. The method of claim 11 wherein the extrusion and the light transfer medium are potted with one of an epoxy or a sealant to provide waterproofing.

21. A lighting unit housing a plurality of light source dies and having a light transfer medium controlling collimation of light emitted from each of the light source dies and averaging color temperatures of light emitted from the light source dies, the lighting unit comprising:

an extrusion forming a channel having an open length, the extrusion housing a plurality of light source dies and a printed circuit board comprising a drive system controlling one or more of the light source dies of the plurality of light source dies mounted on the printed circuit board inside the extrusion;

a first light source die of the plurality of light source dies emitting a first light having a first color temperature different from a second color temperature of a second light emitted by a second light source die of the plurality of light source dies;

a reflector on an upper surface of the printed circuit board inside the extrusion, the reflector reflecting portions of the first light and the second light;

a light transfer medium positioned above the plurality of the plurality of light source dies and covering at least a part of the open length of the extrusion, the light transfer medium having a bottom side and a rounded top side having a diameter, the height of the extrusion is configured to position the bottom side of the light transfer medium a predetermined distance of an air gap from a surface of each of the light source dies of the plurality of light source dies;

the diameter of the rounded top side is configured in combination with the predetermined distance of the air gap between the surface of each of the light source dies and the light transfer medium to establish a particular emitting angle of a plurality of emitting angles of the first light and the second light traversing the light transfer medium; and

the light transfer medium based on the diameter and the distance of the air gap between the surface of each of the light source dies and the light transfer medium collecting and collimating along the length of the light transfer medium covering the extrusion the first light and the second light within the emitting angle and averaging the first color temperature of a first portion of the first light with the second color temperature of a second portion of the second light.

22. The lighting unit of claim 21 wherein the channel further comprises a plurality of sides wherein at least one of the plurality of sides comprises a first reflective surface and wherein the first portion of the first light and the second portion of the second light reflect off the first reflective surface toward the bottom side of the light transfer medium.

23. The lighting unit of claim 22 further comprising a second reflective surface wherein the second portion of the second light reflects of the second reflective surface toward the bottom side of the light transfer medium.