Lamp with LED array and thermal coupling medium

• US 9,482,421 B2
• Filed: 12/30/2011
• Issued: 11/01/2016
• Est. Priority Date: 12/30/2011
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Negley, Gerald H., Athalye, Praneet, Coleman, Thomas G.
• Primary Examiner(s): MAY, ROBERT J
• Application Number:
  US13/340,928
• Publication Number:
  US 20130170175A1
• Time in Patent Office: 1,768 Days
• Field of Search: 362/294, 362/373, 362/267
• 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 9/233 specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps
• 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 29/506 of globes, bowls or cover glasses
• CPC Class Codes: F21V 29/54 using thermoelectric means, e.g. Peltier elements
• CPC Class Codes: F21V 29/58 characterised by the coolants
• CPC Class Codes: F21V 3/00 Globes; Bowls; Cover glasses with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506
• CPC Class Codes: F21V 3/12 the coatings comprising photoluminescent substances
• CPC Class Codes: F21Y 2107/00 Light sources with three-dimensionally disposed light-generating elements
• CPC Class Codes: F21Y 2107/90 on two opposite sides of supports or substrates
• 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: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A lamp with an LED array is disclosed. The centralized nature of the LEDs allows the LEDs to be configured in a filament-like way using a supporting power structure, near the central portion of the optical envelope of the lamp. In example embodiments, the LEDs are cooled by a fluid medium to enable the LEDs to maintain appropriate mechanical stability and operating temperature. In some embodiments, the lamp operates at a power of at least 5 watts. Since the LED array can be centralized to form a filament-like structure, the light pattern from the lamp is not adversely affected by the presence of a heat sink or mechanical supporting parts. In some embodiments, phosphor is used provide wavelength conversion. The phosphor can be suspended within the optically transmissive fluid medium, placed remotely in the lamp structure, or applied to un-encapsulated LED die.

Claims

1. A lamp comprising:

an optically transmissive enclosure;

an array of LEDs disposed in the enclosure on a wire frame assembly with substantially no additional mechanical support, the array of LEDs being operable to emit light when the wire frame assembly is energized;

at least one, sealed inner envelope around the array of LEDs;

a liquid and/or gel to provide thermal coupling to the array of LEDs, at least one portion of the liquid and/or gel confined to the at least one inner envelop and at least another portion of the liquid and/or gel between the at least one inner envelope and the optically transmissive enclosure; and

a phosphor suspended in either the liquid and/or gel confined to the at least one inner envelope or the liquid and/or gel between the at least one inner envelope and the optically transmissive enclosure.

2. The lamp of claim 1 wherein the liquid and/or gel comprises at least one of oil and fluorinated or halogenated liquid or gel.

3. The lamp of claim 2 wherein the liquid and/or gel provides optical coupling to at least one of the array of LEDs and the optically transmissive enclosure.

4. The lamp of claim 1 wherein the lamp takes one of a PAR and an A form factor.

5. The lamp of claim 1 wherein the lamp takes one of a PAR and an A form factor.

6. A lamp comprising:

an optically transmissive enclosure;

an array of LEDs disposed in the enclosure on a wire frame assembly, the array of LEDs further comprising at least a first die and a second die, and a phosphor associated with at least one of the first die and the second die;

at least one, sealed inner envelope around the array of LEDs; and

an index matching medium contained in the enclosure to provide optical and thermal coupling to the array of LEDs;

wherein the first die, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and the second die, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm, and wherein the phosphor, when excited, emits light having a dominant wavelength from 540 to 585 nm and the lamp, when the array of LEDs is energized through the wire frame assembly, operates at a power level of at least about 5 watts.

7. The lamp of claim 6 wherein the index matching medium comprises at least one of oil and fluorinated or halogenated liquid or gel.

8. The lamp of claim 6 wherein the lamp takes one of a PAR and an A form factor.

9. The lamp of claim 6, wherein at least a portion of the liquid and/or gel is confined to the at least one, sealed inner envelope.

10. The lamp of claim 9 wherein the liquid and/or gel confined to the at least one, sealed inner envelope comprises phase change material.

11. A method of making a lamp, the method comprising:

providing an optically transmissive enclosure;

centrally locating an array of LEDs in the enclosure on a wire frame assembly, the array of LEDs further comprising at least at least a first LED and a second LED, wherein the first LED, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and the second LED, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm;

coating at least one of the first LED and the second LED with a phosphor wherein the phosphor, when excited, emits light having a dominant wavelength from 540 to 585 nm;

providing at least one, sealed inner envelope around the array of LEDs;

connecting the wire frame assembly so that the LEDs can be energized through the wire frame assembly to emit light; and

placing an index matching medium in the enclosure so that the fluid medium provides optical and thermal coupling to the LEDs.

12. The method of claim 11 further comprising:

connecting a power supply to the wire frame assembly;

providing an Edison base; and

connecting the Edison base to the power supply.

13. The method of claim 12 further comprising disbursing phosphor particles in the index matching medium.

14. The method of claim 13 wherein the phosphor particles are disbursed in the index matching medium inside the, sealed inner envelope.

15. The method of claim 14 further comprising placing the index matching medium both between the optically transmissive enclosure and the, sealed inner envelope and within the, sealed inner envelope.

16. The method of claim 12 wherein the index matching medium is confined to the, sealed inner envelope.

17. The method of claim 16 wherein the index matching medium is a phase change material.

18. The method of claim 16 further comprising providing a remote phosphor associated with the, sealed inner envelope.

19. A lamp comprising:

an optically transmissive enclosure;

an array of LEDs disposed in the enclosure to be operable to emit light when the array of LEDs is energized, the array of LEDs further comprising at least a first die and a second die, and a phosphor associated with at least one of the first die and the second die; and

a phase change material contained in the enclosure to provide optical coupling to the array of LEDs and/or the optically transmissive enclosure and thermal coupling to the array of LEDs by changing to a gas in a portion of the enclosure that surrounds the array of LEDs and returning to a liquid in a fluid reservoir;

wherein the first die, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and the second die, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm, and wherein the phosphor, when excited, emits light having a dominant wavelength from 540 to 585 nm.

20. The lamp of claim 19 further comprising a supporting power structure connected to the array of LEDs.

21. The lamp of claim 20 wherein the lamp takes one of a PAR and an A form factor.

22. The lamp of claim 19 further comprising at least one inner envelope wherein at least a portion of the phase change material is confined to the at least one inner envelope.