Remote Phosphor LED Lamp with Red Emitters and Diffuser
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Solution Overview
Problem
Conventional LED lamps face issues with heat dissipation and aesthetic concerns due to the placement of phosphor materials, leading to reduced efficiency and acceptance, especially when using remote phosphor arrangements which can result in elevated operating temperatures and undesirable visual characteristics.
Innovation Solution
The use of a separate diffusing layer and remote wavelength conversion materials in combination with a heat sink structure allows for efficient heat dissipation and omnidirectional emission patterns, masking the phosphor appearance when not illuminated, and reducing the need for expensive red phosphors by using red emitting LEDs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If phosphor materials are placed close to LED chips for wavelength conversion, then conversion efficiency is improved, but operating temperature increases and heat dissipation becomes difficult
Solution Approach 1:
The patent separates the phosphor material from the LED chip by placing it on the inner surface of the transparent envelope away from the chip. This spatial segmentation reduces thermal coupling between the heat-generating LED and the phosphor, lowering operating temperature while maintaining conversion efficiency through optimized optical path design.
Solution Approach 2:
The patent introduces an optical intermediary (light guide structure or reflective surfaces) to transfer energy from the LED to the phosphor without direct thermal contact. This intermediary enables efficient wavelength conversion while acting as a thermal barrier, resolving the contradiction between conversion efficiency and heat management.
2Use of energy by moving object
If phosphor materials are placed close to LED chips, then conversion efficiency is improved, but aesthetic appearance deteriorates due to visible phosphor color
Solution Approach 1:
The patent extracts the phosphor material from its traditional location near the LED chip and relocates it to the inner surface of the transparent envelope. This extraction separates the functional role (wavelength conversion) from the aesthetic concern (visible phosphor color), allowing efficient conversion while hiding the phosphor's natural color through the transparent envelope design.
Solution Approach 2:
The patent utilizes the transparent envelope to mask the phosphor's natural color appearance. By positioning the phosphor on the inner surface and using the envelope's transparency, the design achieves aesthetic appeal while maintaining the phosphor's wavelength conversion function, effectively managing the color perception issue.
3Illumination intensity
If conventional LED packages with reflective cups are used, then light directionality is improved, but optical losses increase due to reflection absorption
Solution Approach 1:
The patent replaces the mechanical reflective cup system with an optical solution using the transparent envelope and internal light guiding structures. This substitution eliminates the energy losses associated with reflective surfaces while maintaining light directionality through refractive index matching and geometric optical design.
Solution Approach 2:
The patent employs composite optical structures combining transparent envelope materials with specific refractive index properties and internal light guiding elements. This composite approach achieves effective light directionality without the energy losses inherent in reflective metal cup systems, resolving the contradiction between directionality and optical efficiency.
4Illumination intensity
If red phosphors are used for wavelength conversion, then color rendering is improved, but manufacturing costs increase
Solution Approach 1:
The patent changes the excitation parameter by using blue LED chips (higher energy) to excite the phosphor, rather than using red LEDs directly. This parameter change enables the use of more cost-effective phosphor materials while achieving superior color rendering through the wavelength conversion process, resolving the cost-quality contradiction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables the creation of efficient, reliable, and cost-effective LED lamps with omnidirectional emission patterns, improved heat management, and enhanced aesthetic appeal, while reducing power consumption and manufacturing costs.
Implementation Method 1
A conversion material is provided that is spaced from the first and second LEDs with light from the first and second LEDs passing through the conversion material. The conversion material absorbs at least some of the light from the second LED and re-emits light at a third respective peak emission.
Implementation Method 2
The use of a separate diffusing layer and remote wavelength conversion materials in combination with a heat sink structure allows for efficient heat dissipation
Implementation Method 3
a first LED emitting light at a first peak emission and a second LED emitting light at a second respective peak emission
Data Source
AI summary
Lamps and bulbs are disclosed generally comprising different combinations and arrangement of a light source, one or more wavelength conversion materials, regions or layers which are positioned separately or remotely with respect to the light source, 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 a co-planar arrangement of LEDs. Additionally, this arrangement allows aesthetic masking or concealment of the appearance of the conversion regions or layers when the lamp is not illuminated. Some embodiments of the present invention utilize LED chips to provide one or more lighting components instead of providing the components through phosphor conversion. This can provide for lamps that can be operated with lower power and can be manufactured at lower cost. In one embodiment, a red lighting component can be provided by red emitting LEDs as opposed to a red conversion material.