Illumination apparatus

• US 9,557,034 B2
• Filed: 10/20/2011
• Issued: 01/31/2017
• Est. Priority Date: 10/21/2010
• Status: Active Grant

• Current Assignee: Optovate Ltd. (Reald Spark, LLC)
• Original Assignee: Optovate Ltd. (Reald Spark, LLC)
• Inventors: Woodgate, John Graham, Harrold, Jonathan
• Primary Examiner(s): Coughlin, Andrew
• Assistant Examiner(s): Ulanday, Meghan
• Application Number:
  US13/880,455
• Publication Number:
  US 20130258663A1
• Time in Patent Office: 1,930 Days
• Field of Search: 362/236, 362/245, 362/253, 362/299, 362/300
• US Class Current: 1/1
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• 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 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: F21K 9/69 Details of refractors forming part of the light source
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 17/00 Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages of light sources or light holders F21V19/00
• CPC Class Codes: F21V 23/002 Arrangements of cables or conductors inside a lighting device, e.g. means for guiding along parts of the housing or in a pivoting arm
• CPC Class Codes: F21V 5/007 Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane combination of two or more refractors F21V5/008
• CPC Class Codes: F21V 9/30 Elements containing photoluminescent material distinct from or spaced from the light source shades F21V1/17; globes, bowls or cover glasses F21V3/08, F21V3/12; refractors F21V5/10; reflectors F21V7/26, F21V7/30; elements with provision for controlling the spectral properties or intensity F21V9/40
• CPC Class Codes: F21Y 2101/00 Point-like light sources
• CPC Class Codes: F21Y 2113/13 comprising an assembly of point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G02B 19/0028 refractive and reflective surfaces, e.g. non-imaging catadioptric systems
• CPC Class Codes: G02B 19/0066 in the form of an LED array
• CPC Class Codes: G02F 1/133603 with LEDs
• CPC Class Codes: G02F 1/133605 including specially adapted reflectors
• CPC Class Codes: G02F 1/133607 the light controlling member including light directing or refracting elements, e.g. prisms or lenses
• CPC Class Codes: G02F 1/133612 Electrical details
• CPC Class Codes: G09G 3/2088 with use of a plurality of processors, each processor controlling a number of individual elements of the matrix
• CPC Class Codes: H01L 21/268 : using electromagnetic radiation, e.g. laser radiation
• CPC Class Codes: H01L 22/20 : Sequence of activities consisting of a plurality of measurements, corrections, marking or sorting steps
• CPC Class Codes: H01L 2224/16225 : the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2224/73265 : Layer and wire connectors
• CPC Class Codes: H01L 24/32 : of an individual layer connector
• CPC Class Codes: H01L 25/0753 : the devices being arranged next to each other
• CPC Class Codes: H01L 25/167 : comprising optoelectronic devices, e.g. LED, photodiodes
• 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 2924/01322 : Eutectic Alloys, i.e. obtained by a liquid transforming into two solid phases
• CPC Class Codes: H01L 2924/09701 : Low temperature co-fired ceramic [LTCC]
• CPC Class Codes: H01L 2924/12035 : Zener diode
• CPC Class Codes: H01L 2924/12042 : LASER
• CPC Class Codes: H01L 2924/1301 : Thyristor
• CPC Class Codes: H01L 2924/13033 : TRIAC - Triode for Alternating Current - A bidirectional switching device containing two thyristor structures with common gate contact
• CPC Class Codes: H01L 2924/14 : Integrated circuits
• CPC Class Codes: H01L 2924/15787 : Ceramics, e.g. crystalline carbides, nitrides or oxides
• CPC Class Codes: H01L 2924/15788 : Glasses, e.g. amorphous oxides, nitrides or fluorides
• CPC Class Codes: H01L 2924/3512 : Cracking
• CPC Class Codes: H01L 2933/0033 : relating to semiconductor body packages
• CPC Class Codes: H01L 2933/0041 : relating to wavelength conversion elements
• CPC Class Codes: H01L 2933/005 : relating to encapsulations
• CPC Class Codes: H01L 2933/0058 : relating to optical field-shaping elements
• CPC Class Codes: H01L 2933/0066 : relating to arrangements for conducting electric current to or from the semiconductor body
• CPC Class Codes: H01L 33/0093 : Wafer bonding; Removal of the growth substrate
• CPC Class Codes: H01L 33/0095 : Post-treatment of devices, e.g. annealing, recrystallisation or short-circuit elimination
• CPC Class Codes: H01L 33/08 : with a plurality of light emitting regions, e.g. laterally discontinuous light emitting layer or photoluminescent region integrated within the semiconductor body H01L27/15 takes precedence
• CPC Class Codes: H01L 33/504 : Elements with two or more wavelength conversion materials
• 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 33/56 : Materials, e.g. epoxy or silicone resin
• CPC Class Codes: H01L 33/58 : Optical field-shaping elements
• CPC Class Codes: H01L 33/60 : Reflective elements
• CPC Class Codes: H01L 33/62 : Arrangements for conducting electric current to or from the semiconductor body, e.g. lead-frames, wire-bonds or solder balls
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing

Abstract

An illumination apparatus comprises a plurality of LEDs aligned to an array of directional optical elements wherein the LEDs are substantially at the input aperture of respective optical elements. An electrode array is formed on the array of optical elements to provide at least a first electrical connection to the array of LED elements. Advantageously such an arrangement provides low cost and high efficiency from the directional LED array.

Claims

1. An illumination apparatus whose primary purpose is illumination as opposed to display, comprising:

an optical element array structure; and

a light emitting element structure;

the optical element array structure and the light emitting element structure are each respective separate structures before being assembled together;

the optical element array structure comprising a plurality of optical elements, wherein the optical elements are catadioptric, reflective or refractive, and the optical elements are arranged in an array;

the light emitting element structure comprising a substrate and a plurality of light emitting elements arranged on the substrate;

the optical element array structure and the light emitting element structure being arranged such that the optical elements of the optical element array structure are aligned with the light emitting elements of the light emitting element structure; and

the optical element array structure further comprises optical element electrodes disposed on a bottom part of the optical element array structure that provide an electrical connection to the plurality of light emitting elements,

wherein a gap is defined between at least a portion of the optical element electrodes and the light emitting element structure.

2. An illumination apparatus according to claim 1, wherein the optical element electrodes are, at least in part, positioned on a part of the optical elements that has a shape profile or a material composition profile of the optical element that is related to the catadioptric, reflective or refractive characteristic of the optical element.

3. An illumination apparatus according to claim 2 wherein the part of the optical elements comprises a transparent polymer material composition.

4. An illumination apparatus according to claim 2 wherein the optical elements comprise a wavelength conversion material.

5. An illumination apparatus according to claim 1 wherein for at least some of the plurality of light emitting elements a first electrical connection to the light emitting element is provided by a first optical element electrode and a second electrical connection to the light emitting element is provided by a second optical element electrode.

6. An illumination apparatus, according to claim 1 wherein for at least some of the plurality of light emitting elements a first electrical connection to the light emitting element is provided by the optical element electrode and a second electrical connection to the light emitting element is provided by a support substrate electrode.

7. An illumination apparatus according to claim 1 wherein at least one optical element electrode is formed on a substantially planar surface formed between at least two optical elements of the optical element array structure.

8. An illumination apparatus according to claim 1 wherein the optical element electrodes are, at least in part, positioned on a part of the optical elements that has a shape profile substantially arranged to provide a contact between the optical element electrodes and substrate electrodes.

9. An illumination apparatus according to claim 1 wherein at least one of the substrate or optical array further comprises electronic components arranged in the region between light emitting elements of the light emitting element array.

10. An illumination apparatus according to claim 1 wherein the optical element structure and light emitting element structure cooperate to provide at least one light emitting element string comprising at least two light emitting elements connected in series and at least one current source is multiplexed to multiple strings of light emitting elements.

11. A method of manufacturing an illumination apparatus whose primary purpose is illumination as opposed to display, the method comprising:

providing an optical element array structure, the optical element array structure comprising a plurality of optical elements, the plurality of optical elements are catadioptric, reflective or refractive, and the plurality of optical elements are arranged in an array;

providing a light emitting element structure, the optical element array structure and the light emitting element structure provided as respective separate structures, the light emitting element structure comprising a substrate and a plurality of light emitting elements arranged on the substrate and the optical element array structure further comprising optical element electrodes disposed on a bottom part of the optical element array structure that provide an electrical connection to the plurality of light emitting elements; and

assembling the optical element array structure with the light emitting element structure such that the optical elements of the optical element array structure are aligned with the light emitting elements of the light emitting element structure,

wherein the assembling the optical element array structure with the light emitting element structure further comprises assembling the optical element array structure with the light emitting element structure such that a gap is defined between at least a portion of the optical element electrodes and the light emitting element structure.

12. An array of optical elements, comprising:

the optical elements are catadioptric directional optical elements;

the array of optical elements being adapted to be aligned with a plurality of light emitting elements arranged in an array to provide an illumination apparatus;

wherein;

the array of optical elements comprises optical element electrodes disposed on a bottom part of the optical elements to provide a first electrical connection to the plurality of light emitting elements, and

the optical element electrodes are disposed on the bottom part of the optical elements to provide a gap between at least a portion of the optical element electrodes and the plurality of light emitting elements when coupled to the plurality of light emitting elements.

13. An array of optical elements according to claim 12 wherein the array of optical elements are adapted to be aligned with the plurality of light emitting elements to provide a light output cone from the illumination apparatus with an output cone angle of less than 30 degrees.