LED lamp or bulb with remote phosphor and diffuser configuration with enhanced scattering properties

• US 8,882,284 B2
• Filed: 01/31/2011
• Issued: 11/11/2014
• Est. Priority Date: 03/03/2010
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Tong, Tao, Le Toquin, Ronan, Keller, Bernd, Tarsa, Eric, Youmans, Mark, Lowes, Theodore, Medendorp, Nicholas W. Jr., Van De Ven, Antony, Negley, Gerald
• Primary Examiner(s): RALEIGH, DONALD L
• Application Number:
  US13/018,291
• Publication Number:
  US 20110267801A1
• Time in Patent Office: 1,380 Days
• Field of Search: 36231101-31105, 362543-549, 362/555, 362/800, 36224901-24903, 313110-117
• US Class Current: 362/84
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• 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 13/08 the elements being filters or photoluminescent elements and reflectors
• CPC Class Codes: F21V 29/505 of reflectors
• CPC Class Codes: F21V 29/51 using condensation or evaporation of a fluid, e.g. heat pipes
• CPC Class Codes: F21V 29/767 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• CPC Class Codes: F21V 29/773 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/85 characterised by the material liquid coolants F21V29/56
• CPC Class Codes: F21V 3/00 Globes; Bowls; Cover glasses with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506
• CPC Class Codes: F21V 3/02 characterised by the shape
• CPC Class Codes: F21V 3/08 the material comprising photoluminescent substances
• CPC Class Codes: F21V 3/12 the coatings comprising photoluminescent substances
• CPC Class Codes: F21V 9/32 characterised by the arrangement of the photoluminescent material
• CPC Class Codes: F21V 9/38 Combination of two or more photoluminescent elements of different materials
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

An LED lamp or bulb is disclosed that comprises a light source, a heat sink structure and an optical cavity. The optical cavity comprises a phosphor carrier having a conversions material and arranged over an opening to the cavity. The phosphor carrier comprises a thermally conductive transparent material and is thermally coupled to the heat sink structure. An LED based light source is mounted in the optical cavity remote to the phosphor carrier with light from the light source passing through the phosphor carrier. A diffuser dome is included that is mounted over the optical cavity, with light from the optical cavity passing through the diffuser dome. The properties of the diffuser, such as geometry, scattering properties of the scattering layer, surface roughness or smoothness, and spatial distribution of the scattering layer properties may be used to control various lamp properties such as color uniformity and light intensity distribution as a function of viewing angle.

Claims

1. A solid state lamp, comprising:

a light emitting diode (LED) based light source;

a remote wavelength conversion material carrier spaced from said LED light source;

a diffuser distinct from said remote wavelength conversion material carrier wherein said diffuser comprises a geometry and light scattering properties configured to disperse the light from said LED light source and wavelength conversion material carrier in a substantially omnidirectional emission pattern, wherein said diffuser geometry comprises a neck at its base, wherein at least a portion of said remote wavelength conversion material carrier is at the base of said diffuser;

wherein said conversion material carrier comprises a carrier layer and a phosphor layer.

2. The solid state lamp of claim 1, wherein said diffuser further comprising a bulb portion.

3. The solid state lamp of claim 1, wherein said light scattering properties comprise non-uniform light scattering properties.

4. The solid state lamp of claim 1, wherein said LED light source comprises a plurality of co-planar LEDs and said remote wavelength conversion material carrier comprises a substantially planar shape.

5. The solid state lamp of claim 1, wherein said LED light source comprises a plurality of co-planar LEDs and said remote wavelength conversion material carrier comprises a substantially planar shape, wherein said diffuser has a lower portion which transmits more light than the corresponding upper portion.

6. The solid state lamp of claim 1, wherein said LED light source comprises a plurality of co-planar LEDs and said remote wavelength conversion material carrier comprises a substantially planar shape, wherein said diffuser comprises a substantially globe shape having a lower portion which transmits more light than the corresponding upper portion.

7. The solid state lamp of claim 1, wherein the emission from said LED based light source and said remote wavelength conversion material carrier is forward directed.

8. The solid state lamp of claim 1, wherein the emission from said LED based light source and said remote wavelength conversion material carrier is forward directed, wherein said diffuser has a lower portion which transmits more light than the corresponding upper portion.

9. The solid state lamp of claim 1, wherein the emission from said LED based light source and said remote wavelength conversion material carrier is forward directed, wherein said diffuser comprises a substantially globe shape having a lower portion which transmits more light than the corresponding upper portion.

10. The solid state lamp of claim 1, wherein said remote wavelength conversion material carrier absorbs light from said light source and re-emits light in a dispersed pattern, wherein said diffuser comprises a globe shape.

46. The solid state lamp of claim 1, wherein said remote wavelength conversion material comprises substantially planar top and bottom surfaces.

47. The solid state lamp of claim 1, wherein said remote wavelength conversion material carrier is disk-shaped.

48. The solid state lamp of claim 1, wherein said LED based light source is in a cavity below said remote wavelength conversion material carrier and said diffuser.

54. The solid state lamp of claim 1, wherein said remote wavelength conversion material comprises a three-dimensional shape, wherein said diffuser comprises a substantially globe shape.

55. The solid state lamp of claim 1, wherein said remote wavelength conversion material comprises a three-dimensional shape, wherein said diffuser comprises a lower portion which transmits more light than the corresponding upper portion.

56. The solid state lamp of claim 1, wherein said remote wavelength conversion material comprises a three-dimensional shape, wherein said diffuser comprises a substantially globe shape having a lower portion which transmits more light than the corresponding upper portion.

57. The solid state lamp of claim 1, wherein said diffuser comprises a three dimensional shape having surface regions which transmit more light relative to other surface regions.

11. A solid state lamp, comprising:

a forward emitting light emitting diode (LED) based light source;

a substantially flat remote phosphor carrier spaced from said LED light source;

a diffuser distinct from said remote phosphor carrier, said diffuser comprising a scattering material and comprising a geometry configured to disperse light from said LED light source and said phosphor carrier in a substantially uniform lamp emission pattern of light, wherein said diffuser geometry comprises a neck at its base, wherein at least a portion of said phosphor carrier is at the base of said diffuser.

12. The solid state lamp of claim 11, that is narrow at its base.

13. The solid state lamp of claim 11, wherein said diffuser has regions of non-uniform transparencies.

14. The solid state lamp of claim 11, wherein said diffuser has a lower portion which transmits more light than the corresponding upper portion.

15. The solid state lamp of claim 11, wherein said diffuser comprises a substantially globe shape having a lower portion which transmits more light than the corresponding upper portion.

16. The solid state lamp of claim 11, wherein the emission from said LED based light source and said remote phosphor carrier is forward directed, wherein said diffuser has a lower portion which transmits more light than the corresponding upper portion.

17. The solid state lamp of claim 11, wherein said remote phosphor carrier absorbs light from said light source and re-emits light in a dispersed pattern, wherein said diffuser comprises a globe shape.

18. The solid state lamp of claim 11, wherein said diffuser comprises a bulb with a scattering material.

19. The solid state lamp of claim 18, wherein said diffuser comprises a scattering film, layer or region.

20. The solid state lamp of claim 18, wherein said diffuser comprises a layer of scattering particles.

21. The solid state lamp of claim 20, wherein said layer of scattering particles comprises non-uniform scatter properties.

22. The solid state lamp of claim 20, wherein said layer of scattering particles has one or more regions that are more transparent.

23. The solid state lamp of claim 20, wherein said layer of scattering particles comprise one or more regions that are smooth.

24. The solid state lamp of claim 20, wherein said layer of scattering particles comprise one or more regions that are roughened.

25. The solid state lamp of claim 20, wherein said layer of scattering particles comprises an isotropic scattering properties.

26. The solid state lamp of claim 11, wherein said diffuser comprises a bulb with a layer of scattering particles.

27. The solid state lamp of claim 26, wherein said layer of scattering particles is on the inside surface or outside surface of said bulb, or both.

28. The solid state lamp of claim 26, wherein said layer of scattering particles is within said bulb.

29. The solid state lamp of claim 26, wherein said bulb comprises glass or plastic.

49. The solid state lamp of claim 11, wherein said remote phosphor carrier comprises a carrier layer and a phosphor layer.

50. The solid state lamp of claim 11, wherein said remote phosphor carrier comprises a phosphor-binder mixture.

51. The solid state lamp of claim 11, wherein said remote phosphor carrier is disk-shaped.

58. The solid state lamp of claim 11, wherein said remote phosphor comprises a three-dimensional shape, wherein said diffuser comprises a lower portion which transmits more light than the corresponding upper portion.

30. A solid state lamp, comprising:

a light emitting diode (LED) based light source;

a three dimensional remote phosphor carrier comprising a neck and spaced from said LED light source;

a three dimensional diffuser distinct from said remote phosphor carrier and having a shape and varying scattering properties configured such that light emitted from the diffuser has reduced variation in spatial emission intensity profile over an angular range compared to the light emitted from the remote phosphor carrier, wherein said diffuser comprises a neck, wherein at least a portion of said remote phosphor carrier is at the base of said diffuser.

31. The solid state lamp of claim 30, wherein said diffuser has a lower portion which transmits more light than the corresponding upper portion.

32. The solid state lamp of claim 30, wherein said diffuser comprises a substantially globe shape.

33. The solid state lamp of claim 30, wherein said diffuser comprises a lower portion which transmits more light than the corresponding upper portion.

34. The solid state lamp of claim 30, wherein said diffuser comprises a bulb with a scattering material.

35. The solid state lamp of claim 30, wherein said diffuser comprises a scattering film, layer or region.

36. The solid state lamp of claim 30, wherein said diffuser comprises a layer of scattering particles.

37. The solid state lamp of claim 36, wherein said layer of scattering particles comprises non-uniform scatter properties.

38. The solid state lamp of claim 36, wherein said layer of scattering particles has one or more regions of reduced scattering properties.

39. The solid state lamp of claim 36, wherein said layer of scattering particles has a region of reduced scattering properties at the base of said diffuser.

40. The solid state lamp of claim 39, wherein the exposed surface of the said layer of scattering particles is smooth.

41. The solid state lamp of claim 39, wherein the exposed surface of the said layer of scattering particles is roughened.

42. The solid state lamp of claim 30, wherein said diffuser comprises a bulb with a layer of scattering particles.

43. The solid state lamp of claim 42, wherein said layer of scattering particles is on the inside surface or outside surface of said bulb, or both.

44. The solid state lamp of claim 42, wherein said layer of scattering particles is within said bulb.

45. The solid state lamp of claim 42, further comprising a heat sink, said bulb extending beyond the edge of said heat sink.

52. The solid state lamp of claim 30, wherein said three dimensional remote phosphor carrier comprises a carrier layer and a phosphor layer.

53. The solid state lamp of claim 30, wherein said three dimensional remote phosphor carrier comprises a phosphor-binder mixture.