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

• US 9,450,162 B2
• Filed: 05/06/2014
• Issued: 09/20/2016
• Est. Priority Date: 07/22/2011
• Status: Active Grant

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Alvarez, Jemssy, Veerasamy, Vijayen S.
• Primary Examiner(s): Hines, Anne
• Assistant Examiner(s): Diaz, Jose M
• Application Number:
  US14/270,494
• Publication Number:
  US 20140239333A1
• Time in Patent Office: 868 Days
• Field of Search: 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, 313498-512
• 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: 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. An apparatus, comprising:

a first glass substrate having at least one cavity formed therein, each said cavity (a) increasing in diameter or distance from a first end thereof to a second end thereof, and (b) having a reflective surface;

a lens disposed completely within the cavity and being located at the first end of the cavity;

at least one light emitting diode (LED) at, or proximate to the first end of a respective one of said cavities so as to enable the reflective surface of the associated cavity to reflect at least some light emitted from the respective LED;

a phosphor-inclusive material disposed over the at least one LED and over the first end;

wherein the reflective surface of each said cavity is configured to conserve é

tendue of the light from the respective LED; and

wherein each said LED is configured to produce light in accordance with a first spectrum, the phosphor-inclusive material has a second spectrum, and light exiting the apparatus has a third spectrum.

2. The apparatus of claim 1, wherein each said cavity has a parabolic side wall when viewed in cross section.

3. The apparatus of claim 1, wherein the reflected light exiting the second end of each said cavity is substantially collimated so as to allow for 10-30 degrees of distribution.

4. The apparatus of claim 1, further comprising a second substrate supporting the phosphor-inclusive material, the second substrate being oriented above the second end of each said cavity.

5. The apparatus of claim 4, wherein the phosphor-inclusive material is sputter deposited, directly or indirectly, onto the second substrate.

6. The apparatus of claim 4, wherein the phosphor-inclusive material is embedded in a laminate material laminated to the second substrate.

7. The apparatus of claim 4, wherein the second substrate is curved, such that an apex of the second substrate is positioned away from the at least one LED.

8. The apparatus of claim 4, wherein the lens is a Fresnel lens between the second substrate and the at least one LED, wherein the Fresnel lens is structured to increase diffusion of light from the at least one LED.

9. The apparatus of claim 4, wherein a hermetic seal is formed between the first and second substrates.

10. The apparatus of claim 9, wherein the at least one LED lacks an epoxy cap.

11. The apparatus of claim 1, wherein the phosphor-inclusive material includes a white phosphor selected from among Ce:

YAG and MN;

ZnGeO₄.

12. The apparatus of claim 1, wherein the LED is a blue LED and the phosphor component includes yellow phosphor.

13. The apparatus of claim 1, wherein the at least one LED is a bare die LED.

14. The apparatus of claim 1, wherein a CRI of light exiting the phosphor-inclusive material is at least 95%.

15. A lighting system comprising the apparatus of claim 1.

16. A lighting system comprising a plurality of interconnected apparatuses, wherein each said apparatus is the apparatus of claim 1.

17. A method of making a light fixture, the method comprising:

forming at least one cavity in a glass substrate, each said cavity increasing in diameter or distance from a first end thereof to a second end thereof;

disposing a reflective element on a surface of the at least one cavity;

disposing a lens completely within the cavity;

locating a light emitting diode (LED) at or proximate to the first end of each said cavity so as to enable the associated reflective element to reflect at least some light emitted from the respective LED; and

disposing a phosphor-inclusive material over the first end.

18. The method of claim 17, further comprising disposing a collimating lens within each said cavity, wherein the reflected light exiting the second end of each said cavity is substantially collimated so as to allow for 10-30 degrees of distribution, and

wherein the reflective surface of each said cavity is configured to conserve é

tendue of the light from the respective LED.