Remote phosphor element filled with transparent material and method for forming multisection optical elements

• US 9,360,188 B2
• Filed: 02/20/2014
• Issued: 06/07/2016
• Est. Priority Date: 02/20/2014
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Kircher, Deborah, Lowes, Theodore, Fini, Paul T., Keller, Bernd
• Primary Examiner(s): Pham, Long
• Application Number:
  US14/185,123
• Publication Number:
  US 20150233544A1
• Time in Patent Office: 838 Days
• US Class Current: 1/1
• 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: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 13/08 the elements being filters or photoluminescent elements and reflectors
• CPC Class Codes: F21V 29/502 characterised by the adaptation for cooling of specific components
• CPC Class Codes: F21V 3/08 the material 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: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2224/73265 Layer and wire connectors
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 2933/0041 relating to wavelength conversion elements
• 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 33/644 in intimate contact or integrated with parts of the device other than the semiconductor body

Abstract

Lighting components and fixtures having optical elements with multiple portions are disclosed. A wavelength conversion element can be mounted over a source, the wavelength conversion element including wavelength conversion material remote to the source, such as on or near the outside surface of a conversion element. The element can be filled with a transparent and thermally conductive material which thermally couples the remote conversion material and the source, aiding in thermal dissipation and improving fixture efficacy. An optical element can be formed by using an embossing plate to form a first portion, partially curing the first portion, removing the embossing plate, and introducing material to form a second portion.

Claims

1. A light emitting device, comprising:

a light source; and

a wavelength conversion element comprising a filler portion and a phosphor portion on said filler portion, said phosphor portion comprising a wavelength conversion material;

wherein said phosphor portion is remote to said light source; and

wherein said phosphor portion is thermally coupled to said light source;

wherein said light source and said wavelength conversion element are on a heat sink,

wherein said phosphor portion is separated from said light source by at least about 0.5 mm.

2. The light emitting device of claim 1, wherein said filler portion thermally couples said phosphor portion to said light source.

3. The light emitting device of claim 1, wherein said filler portion is configured to dissipate heat from said phosphor portion conductively and convectively.

4. The light emitting device of claim 1, wherein said filler portion comprises glass.

5. The light emitting device of claim 4, wherein said glass has a melting temperature of approximately 300°

C. or below.

6. The light emitting device of claim 1, wherein said filler portion and said phosphor portion have approximately equal indices of refraction.

7. The light emitting device of claim 1, wherein said filler portion comprises a solid phase material.

8. The light emitting device of claim 1, wherein said filler portion comprises a liquid.

9. The light emitting device of claim 1, wherein said light emitting device is configured such that said filler material is a solid phase material during periods of non-operation and a liquid material during periods of operation.

10. The light emitting device of claim 1, wherein said wavelength conversion element has a width larger than a width of said source.

11. The lighting emitting device of claim 1, wherein said wavelength conversion element comprises scattering particles.

12. The lighting emitting device of claim 1, wherein said filler portion comprises scattering particles.

13. A wavelength conversion component, said component comprising:

an outer portion comprising a wavelength conversion material; and

an inner portion comprising a substantially transparent and thermally conductive material;

wherein said component is substantially solid;

wherein said outer portion and said inner portion comprise a binder.

14. The component of claim 13, wherein said binder is silicone.

15. The component of claim 13, wherein said component is substantially frustospherical.

16. The component of claim 13, wherein said inner portion is liquid.

17. The component of claim 13, wherein said inner portion has a minimum width of at least 0.1 mm.

18. An optical device, comprising:

an optical element, said optical element comprising;

a molded outer portion comprising a wavelength conversion material; and

a molded inner portion on and distinct from said molded outer portion;

wherein said inner portion has a higher index of refraction than said outer portion.

19. The optical device of claim 18, further comprising a source;

wherein said optical element is overmolded onto said source.

20. The optical device of claim 18, wherein said outer and inner portions have different compositions.

21. The optical device of claim 18, wherein said optical element further comprises a molded innermost portion on and distinct from said molded inner portion.

22. The optical device of claim 21, wherein said outer portion comprises a first phosphor and said inner portion comprises a second phosphor.

23. The optical device of claim 21, wherein said innermost portion has a higher index of refraction than said inner portion and said inner portion has a higher index of refraction than said outer portion.

24. The optical device of claim 21, wherein said molded outer portion is integral with said molded inner portion.