Tunable remote phosphor constructs

• US 9,324,924 B2
• Filed: 03/03/2011
• Issued: 04/26/2016
• Est. Priority Date: 03/03/2011
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Van De Ven, Antony P.
• Primary Examiner(s): PAYNE, SHARON E
• Application Number:
  US13/039,743
• Publication Number:
  US 20120224363A1
• Time in Patent Office: 1,881 Days
• Field of Search: 313/46, 439/29, 362/311.01, 362/311.06, 362/311.02
• US Class Current: 1/1
• 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 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• 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 3/02 characterised by the shape
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• 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 2933/0041 relating to wavelength conversion elements
• CPC Class Codes: H01L 33/505 characterised by the shape, e.g. plate or foil
• CPC Class Codes: H01L 33/507 the elements being in intimate contact with parts other than the semiconductor body or integrated with parts other than the semiconductor body
• CPC Class Codes: H01L 33/508 having a non-uniform spatial arrangement or non-uniform concentration, e.g. patterned wavelength conversion layer, wavelength conversion layer with a concentration gradient of the wavelength conversion material
• CPC Class Codes: H01L 33/58 Optical field-shaping elements

Abstract

A solid state lighting comprising: at least one LED element positioned on a top surface of a substrate or a submount; and a polygonal structure comprising a plurality of edges forming a plurality of facets configured to receive light from the at least one LED element, the polygonal structure comprising a wavelength converting material, wherein the wavelength converting material is remotely positioned from the at least one LED element.

Claims

1. A solid state lighting device comprising:

at least one LED element positioned on a top surface of a substrate or a submount; and

an optical element comprising an interior surface and an exterior surface with a semi-spherical or spherical shape, the optical element comprising a plurality of facets where each of the plurality of facets comprises a cyclic polygon and each of the plurality of facets comprises a plurality of edges where at least one of the plurality of edges of each of the plurality of facets forms and edge of an adjacent one of the plurality of facets such that the plurality of facets defines the semi-spherical or spherical shape over the entire interior surface and the entire exterior surface of the optical element, the optical element comprising a wavelength converting material and being configured such that the plurality of facets receive light from the at least one LED element substantially simultaneously, wherein the wavelength converting material is remotely positioned from the at least one LED element wherein two or more of the plurality of facets independently comprises at least two different wavelength converting materials or wherein each of two adjacent facets comprises a different wavelength converting material.

2. The solid state lighting device of claim 1, wherein two or more of the plurality of facets independently comprises a predetermined composition of wavelength converting material.

3. The solid state lighting device of claim 1, wherein two or more of the plurality of facets independently comprises a predetermined concentration of wavelength converting material.

4. The solid state lighting device of claim 1, wherein two or more of the plurality of facets independently comprises a predetermined thickness of wavelength converting material.

5. The solid state lighting device of claim 1, wherein two or more of the plurality of facets independently comprises at least two of:

a predetermined composition of wavelength converting material;

a predetermined concentration of wavelength converting material;

a predetermined thickness of wavelength converting material; and

at least two wavelength converting materials in a predetermined spatial arrangement within the facet or neighboring facets.

6. The solid state lighting device of claim 1, comprising at least two LED elements, wherein one or more of the at least two LED elements emit light of different wavelengths.

7. The solid state lighting device of claim 1, comprising at least two LED elements, wherein one or more of the at least two LED elements emit light of different wavelengths and wherein two or more of the plurality of facets independently comprises at least two of:

a predetermined composition of wavelength converting material;

a predetermined concentration of wavelength converting material;

a predetermined thickness of wavelength converting material; and

at least two wavelength converting materials in a predetermined spatial arrangement within the facet or neighboring facets.

8. The solid state lighting device of claim 1, wherein the optical element comprises at least five facets.

9. The solid state lighting device of claim 1, wherein the optical element at least partially surrounds the at least one LED element.

10. The solid state lighting device of claim 1, wherein the cyclic polygon includes n-gons having internal angles greater than 90 degrees up to but less than 180 degrees.

11. The solid state lighting device of claim 1, wherein the ratio of the at least one LED element width and facet width is from 2:

1 to 2000;

1.

12. A method of tuning the color of light produced by a solid state lighting device, the method comprising;

providing at least one LED element emitting one or more primary wavelengths of light;

providing an optical element comprising an interior surface and an exterior surface with a semi-spherical or spherical shape, the optical element comprising a plurality of facets where each of the plurality of facets comprises a cyclic polygon and each of the plurality of facets comprises a plurality of edges where at least one of the plurality of edges of each of the plurality of facets forms and edge of an adjacent one of the plurality of facets such that the plurality of facets defines the semi-spherical or spherical shape over the entire interior surface and the entire exterior surface of the optical element, the optical element configured such that the plurality of facets receive the one or more primary wavelengths of light substantially simultaneously and comprising at least one wavelength converting material, wherein the wavelength converting material is remotely positioned from the at least one LED element;

wherein two or more of the plurality of facets independently comprises at least two different wavelength converting materials or wherein each of two adjacent facets comprises a different wavelength converting material; and

altering at least one of the primary wavelengths of light using the optical element to provide at least one secondary wavelength of light.

13. The method of claim 12, wherein two or more of the plurality of facets independently comprises a predetermined composition of wavelength converting material.

14. The method of claim 12, wherein two or more of the plurality of facets independently comprises a predetermined concentration of wavelength converting material.

15. The method of claim 12, wherein two or more of the plurality of facets independently comprises a predetermined thickness of wavelength converting material.

16. The method of claim 12, wherein two or more of the plurality of facets independently comprises at least two of:

a predetermined composition of wavelength converting material;

a predetermined concentration of wavelength converting material;

a predetermined thickness of wavelength converting material; and

at least two wavelength converting materials in a predetermined spatial arrangement within the facet or neighboring facets.

17. The method of claim 12, comprising at least two LED elements that emit primary wavelengths of light of different wavelengths.

18. The method of claim 17, wherein two or more of the plurality of facets independently comprises at least two of:

a predetermined composition of wavelength converting material;

a predetermined concentration of wavelength converting material;

a predetermined thickness of wavelength converting material; and

at least two wavelength converting materials in a predetermined spatial arrangement within the facet or neighboring facets.

19. The method of claim 17, wherein at least a fraction of the primary wavelengths of light is altered by at least two of the wavelength converting materials.

20. The method of claim 17, wherein at least a fraction of two or more of the primary wavelengths of light of different wavelength are altered by the at least two wavelength converting materials.

21. The method of claim 12, wherein the optical element comprises at least five facets.

22. The method of claim 12, wherein the optical element at least partially surrounds the at least one LED element.

23. The method of claim 12, wherein cyclic polygon includes n-gons having obtuse internal angles greater than 90 degrees up to but less than 180 degrees.

24. The solid state lighting device of claim 12, wherein the ratio of the at least one LED element width and facet width is from 2:

1 to 2000;

1.