LED lighting systems with phosphor subassemblies, and/or methods of making the same

• US 8,742,655 B2
• Filed: 07/22/2011
• Issued: 06/03/2014
• Est. Priority Date: 07/22/2011
• Status: Expired due to Fees

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Veerasamy, Vijayen S., Alvarez, Jemssy
• Primary Examiner(s): Patel, Nimeshkumar
• Assistant Examiner(s): DIAZ, JOSE
• Application Number:
  US13/188,928
• Publication Number:
  US 20130021776A1
• Time in Patent Office: 1,047 Days
• Field of Search: 313498-512, 362/609, 362/612, 362/560, 362/514, 362/516, 362/217.05, 362/241, 362/247, 362/296.01, 362/296.05, 362/296.08, 362/296.1, 362/314, 362/347, 362/350, 362/361
• US Class Current: 313/501
• CPC Class Codes: F21K 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21V 7/0083 Array of reflectors for a cluster of light sources, e.g. arrangement of multiple light sources in one plane combination of two or more reflectors F21V7/0025
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 27/15 including semiconductor components having potential barriers, specially adapted for light emission
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 33/483 Containers
• CPC Class Codes: H01L 33/486 adapted for surface mounting
• CPC Class Codes: H01L 33/502 Wavelength conversion materials
• CPC Class Codes: H01L 33/60 Reflective elements
• CPC Class Codes: H01L 33/642 characterized by the shape

Abstract

Certain example embodiments relate to improved lighting systems and/or methods of making the same. In certain example embodiments, a lighting system includes a glass substrate with one or more apertures. An LED or other light source is disposed at one end of the aperture such that light from the LED directed through the aperture of the glass substrate exits the opposite end of the aperture. Inner surfaces of the aperture have a mirroring material such as silver to reflect the emitted light from the LED. In certain example embodiments, a remote phosphor article or layer is disposed opposite the LED at the other end of the aperture. In certain example embodiment, a lens is disposed in the aperture, between the remote phosphor article and the LED.

Claims

1. A phosphor assembly adapted for use with a lighting apparatus that includes at least one light source, the assembly, moving away from the light source, comprising:

a first glass substrate;

a first index layer;

a phosphor component;

a second index layer; and

a second glass substrate,

wherein emitted light from the at least one light source is partially refracted between the first and second index layers such that at least some of the emitted light passes multiple times through the phosphor component, and

wherein the indices of refraction for the first and second index layers substantially match one another and are selected in dependence of the phosphor component material.

2. The phosphor assembly of claim 1, wherein the phosphor component is 150 to 300 microns in thickness.

3. The phosphor assembly of claim 1, further comprising a hydrophobic layer that structurally seals the phosphor component from outside moisture.

4. The phosphor assembly of claim 1, wherein the phosphor component includes a mix of multiple different phosphor compounds.

5. The phosphor assembly of claim 1, wherein the phosphor component includes at least one of YAG, TAG, Nitrides, or GAL based phosphors.

6. The phosphor assembly of claim 1, wherein the phosphor component is activated via europium.

7. The phosphor assembly of claim 1, wherein the light source is a blue LED.

8. The phosphor assembly of claim 1, wherein the first and second index layers are high index layers with an index of least 1.8.

9. The phosphor assembly of claim 8, wherein the index is at least 2.0.

10. The phosphor assembly of claim 1, wherein the first and second index layers are low index layers with an index between about 1.345 and 1.5.

11. The phosphor assembly of claim 1, wherein the first index layer contacts the first glass substrate.

12. The phosphor assembly of claim 1, wherein the phosphor component is located between and directly contacting the first index layer and the second index layer.