SOLID STATE LAMP WITH LIGHT DIRECTING OPTICS AND DIFFUSER

• US 20130214666A1
• Filed: 02/04/2013
• Published: 08/22/2013
• Est. Priority Date: 08/02/2010
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated), Ideal Industries, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Tarsa, Eric J., Edmond, John A., Leung, Michael S.
• Granted Patent: US 10,451,251 B2
• Time in Patent Office: Days
• US Class Current: 313/46
• 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: F21K 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 13/08 the elements being filters or photoluminescent elements and reflectors
• CPC Class Codes: F21V 29/74 with fins or blades
• 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 3/08 the material comprising photoluminescent substances
• CPC Class Codes: F21V 3/12 the coatings comprising photoluminescent substances
• CPC Class Codes: F21V 7/00 Reflectors for light sources characterised by cooling arrangements F21V29/505
• CPC Class Codes: F21V 7/0058 adapted to cooperate with light sources of shapes different from point-like or linear, e.g. circular light sources
• CPC Class Codes: F21Y 2107/40 on the sides of polyhedrons, e.g. cubes or pyramids
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

Lamps and bulbs are disclosed generally comprising different combinations and arrangements of a light source, a reflective optical element, and a separate diffusing layer. This arrangement allows for the fabrication of lamps and bulbs that are efficient, reliable and cost effective and can provide an essentially omni-directional emission pattern, even with a light source comprised of an arrangement of LEDs. The lamps according to the present invention can also comprise thermal management features that provide for efficient dissipation of heat from the LEDs, which in turn allows the LEDs to operate at lower temperatures. The lamps can also comprise optical elements to help change the emission pattern from the generally directional pattern of the LEDs to a more omni-directional pattern.

Claims

1. A solid state lamp, comprising:

an array of solid state emitters;

a three-dimensional reflective optical element over at least one of said solid state emitters, said optical element modifying the emission pattern of said array to produce a more omni-directional lamp emission pattern.

2. The lamp of claim 1, wherein said optical element comprises reflective surfaces, at least some of said array light reflecting off at least one of said surfaces.

3. The lamp of claim 1, wherein said optical element comprises a cavity.

4. The lamp of claim 3, wherein said cavity extends through the length of said optical element.

5. The lamp of claim 3, wherein said array comprises at least one solid state emitter in said cavity.

6. The lamp of claim 3, wherein said array comprises more than one solid state emitter around the base of said optical element.

7. The lamp of claim 1, wherein the outer surface of said optical element is solid.

8. The lamp of claim 1, wherein said solid state emitters are mounted on a carrier.

9. The lamp of claim 8, wherein said optical element is mounted on said carrier.

10. The lamp of claim 1, wherein at least one of said solid state emitters is coated with phosphor.

11. The lamp of claim 10, wherein all of said solid state emitters are coated with phosphor.

12. The lamp of claim 1, wherein said array comprises red and BSY solid state emitters.

13. The lamp of claim 1, wherein said array of solid state emitters is planar.

14. The lamp of claim 1, wherein said optical element comprises a frustoconical top portion.

15. The lamp of claim 1, wherein said optical element comprises a cylindrical bottom portion.

16. The lamp of claim 14, wherein the outer surface of said frustoconical top portion curves outward.

17. The lamp of claim 1, further comprising a diffuser;

wherein said diffuser comprises a bottom opening; and

wherein the largest diameter of said optical element is equal to or smaller than the diameter of said bottom opening.

18. The lamp of claim 1, further comprising a diffuser surrounding said optical element;

wherein said optical element is within the bottom half of said diffuser.

19. The lamp of claim 14, wherein said frustoconical top portion is angled at approximately 45°

from vertical.

20. The lamp of claim 1, wherein said optical element comprises three or more portions.

21. The lamp of claim 1, further comprising a diffuser around said optical element.

22. The lamp of claim 14, wherein said diffuser reflects at least some of said array light;

and

wherein said reflected light provides forward light emission for said lamp emission pattern.

23. The lamp of claim 21, wherein said diffuser is frustospherical.

24. The lamp of claim 23, wherein said diffuser is oblong.

25. The lamp of claim 21, wherein said diffuser is coated uniformly with diffusing particles or scattering particles.

26. The lamp of claim 25, wherein said diffuser is coated using a fill-and-dump method.

27. The lamp of claim 21, wherein said diffuser a coating of diffusing particles or scattering particles on said diffuser is non-uniform.

28. The lamp of claim 27, wherein a lower portion of said diffuser is coated with more diffusing particles or scattering particles than an upper portion of said diffuser.

29. The lamp of claim 21, wherein said diffuser comprises a roughened surface.

30. The lamp of claim 8, wherein at least some of said solid state emitters are on the perimeter of said carrier.

31. The lamp of claim 8, wherein at least one of said solid state emitters is in said cavity and on said carrier;

and

wherein the rest of said solid state emitters are on the perimeter of said carrier.

32. The lamp of claim 8, wherein at least one of said solid state emitters is in said cavity and on said carrier;

and

wherein the rest of said solid state emitters form a ring around said optical element.

33. The lamp of claim 1, wherein at least some of said solid state emitters are below the top edge of said optical element.

34. The lamp of claim 1, wherein said array comprises eight solid state emitters.

35. The lamp of claim 1, wherein said array comprises 10 solid state emitters.

36. The lamp of claim 1, wherein each of said solid state emitters has an emission profile broader than a Lambertian emission profile.

37. The lamp of claim 1, wherein each of said solid state emitters has a Lambertian emission profile.

38. The lamp of claim 21, wherein said optical element is suspended within said diffuser.

39. The lamp of claim 38, wherein said diffuser comprises at least two separately fabricated diffuser sections.

40. The lamp of claim 39, wherein at least part of said optical element is bonded between at least of said separately fabricated diffuser sections.

41. The lamp of claim 38, wherein said optical element is frustoconical.

42. The lamp of claim 38, wherein said optical element is conical.

43. The lamp of claim 1, wherein said optical element comprises a first surface that is more reflective than a second surface.

44. The lamp of claim 43, wherein said first surface is an outer surface of a frustoconical top section.

45. The lamp of claim 2, wherein said reflective surfaces are white.

46. The lamp of claim 45, wherein said reflective surfaces comprise white plastic sheets.

47. The lamp of claim 45, wherein said reflective surfaces comprise white paper.

48. The lamp of claim 2, wherein said optical element comprises openings in said reflective surfaces to allow array light to pass.

49. The lamp of claim 48, wherein said optical element is flower shaped.

50. The lamp of claim 48, wherein said optical element comprises one or more reflective blades over said array, with light from said array reflecting from said blades.

51. The lamp of claim 1, wherein said openings are holes in said reflective surfaces.

52. The lamp of claim 3, further comprising a phosphor carrier in said cavity.

53. The lamp of claim 3, further comprising a phosphor carrier over said optical element.

54. The lamp of claim 3, further comprising a phosphor carrier outside said optical element.

55. The lamp of claim 1, wherein said lamp fits within an A19 envelope.

56. The lamp of claim 1, wherein said lamp emits an emission pattern that is Energy Star compliant.

57. The lamp of claim 1, further comprising a heat sink;

wherein said heat sink comprises a plurality of fins.

58. The lamp of claim 57, wherein said fins comprise an angled upper portion.

59. The lamp of claim 58, wherein said optical element comprises a frustoconical top portion;

and

wherein the perpendicular of said frustoconical top portion is flatter than said angled upper portion.

60. The lamp of claim 1, wherein said optical element is partially transmissive.

61. The lamp of claim 1, wherein said array comprises at least two different types of solid state emitters.

62. The lamp of claim 1, wherein said array comprises solid state emitters that emit at least two different wavelengths of light.

63. The lamp of claim 5, wherein said at least one solid state emitter in said cavity is different than the rest of said solid state emitters in said array.

64. The lamp of claim 1, wherein said optical element is thermally conductive.

65. The lamp of claim 1, wherein said optical element comprises at least one surface that is a specular reflector.

66. The lamp of claim 1, wherein said optical element comprises at least one surface that is a diffuse reflector.

67. The lamp of claim 1, wherein said optical element comprises at least one surface that is a specular reflector and at least one surface that is a diffuse reflector.

72. The optical element of claim 65, wherein the outer surface of said frustoconical top portion curves outward.

68. A three-dimensional optical element for use in a solid state lamp, said optical element comprising:

a reflective outer surface; and

a cavity for housing a solid state emitter.

69. The optical element of claim 68, further comprising a reflective inner surface.

70. The optical element of claim 68, wherein said optical element comprises a frustoconical top portion.

71. The optical element of claim 68, wherein said optical element comprises a cylindrical bottom portion.

73. The optical element of claim 68, wherein said outer surface is solid.

74. The optical element of claim 68, wherein said frustoconical top portion is angled at approximately 45°

from vertical.

75. The optical element of claim 68, wherein said optical element comprises a first surface that is more reflective than a second surface.

76. The optical element of claim 75, wherein said first surface is an outer surface of a frustoconical top section.

77. The optical element of claim 68, wherein said reflective surface is white.

78. The optical element of claim 68, wherein said reflective surface comprises white plastic sheets.

79. The optical element of claim 68, wherein said reflective surface comprises white paper.