Abstract: A method for forming a flexible sheet of LED light emitters includes forming a micro lens sheet having a plurality of micro lenses, forming a phosphor sheet including a wave-length converting material, forming a flexible circuit sheet, forming a ceramic substrate sheet including a plurality of LED light emitters, and forming a support substrate including a thermally conductive material. The method also includes attaching the above sheets to form a stack including, from top to bottom, the micro lens sheet, the phosphor sheet, the flexible circuit sheet, the ceramic substrate sheet, and the support substrate.

Abstract: A light-emitting diode (LED) emitter module includes a substrate having a plurality of base layers of an electrically insulating material, a plurality of electrical contacts disposed on a top one of the base layer, and a plurality of electrical paths coupled to the electrical contacts, wherein at least a portion of the plurality of electrical paths is disposed between the base layers. The emitter module also includes two or more groups of light-emitting diodes (LEDs), each group having one or more LEDs, and each of the LEDs is coupled to an electrical contact. The electrical paths are configured for feeding separate electrical currents to the groups of LEDs. The emitter module also includes a memory device containing information associating a plurality of output light colors with a corresponding plurality of combinations of electrical currents, each combination specifying an electric current for each of the two or more groups of LEDs.

Abstract: An apparatus is used to tune the color produced by an LED-based lamp to a desired color or color temperature. To support tuning, the lamp can include two or more independently addressable groups of LEDs. Color or color temperature is tuned by controllably dividing an input current among the groups of LEDs. The apparatus determines an optimal division of the input current based on a linear interpolation between measured values of color or color temperature produced by at least two different divisions of the input current.

Abstract: A method for depositing a layer of phosphor-containing material on a plurality of LED (light-emitting diode) dies on a wafer includes disposing a layer of dry photoresist film over a plurality of LED dies on a wafer, disposing a mask layer over the dry photoresist film, and patterning the dry photoresist film to form a plurality of openings in the dry photoresist film to expose a top surface of each of the LED dies. The method also includes depositing a phosphor-containing material on the exposed top surface of each the LED dies using a screen printing process, and removing the patterned dry photoresist film.

Abstract: A method for making a lighting apparatus includes providing a substrate and disposing a light-emitting diode overlying the substrate. The light-emitting diode has a top surface oriented away from the substrate and a plurality of side surfaces. A light-conversion material is provided that includes a substantially transparent base material and a wave-shifting material dispersed in the base material. The concentration of the wave-shifting material can be at least 30%. In an embodiment, the concentration of the wave-shifting material can be approximately 50% or 70%. A predetermined amount of the light-conversion material is deposited on the top surface of the light-emitting diode while the side surfaces are maintained substantially free of the light-conversion material.

Abstract: A method for depositing a layer of phosphor-containing material on a plurality of LED dies includes disposing a template with a plurality of openings on an adhesive tape and disposing each of a plurality of LED dies in one of the plurality of openings of the template. The method also includes disposing a stencil over the template and the plurality of LED dies. The stencil has a plurality of openings configured to expose a top surface of each of the LED dies. Next, a phosphor-containing material is disposed on the exposed top surface of each the LED dies. The method further includes removing the stencil and the template.

Abstract: A lamp includes a single emitter structure having a substrate with 25 or more light emitting diodes (LEDs) arranged thereon and a power rating of 80 Watts or more, a total internal reflection (TIR) lens with a plurality of refractive surface regions disposed on the step-shaped upper surface of the optical body, and a holder having a plurality of tabs disposed along an inside rim of the holder and configured for radial compression fit with a flange of the lens, and three or more support members configured for centering the optical body member with respect to the single emitter structure. A low weight ratio of hardener over base resin below 6 is used, for example, between 1.5:1 to 2.5:1.

Abstract: A total-internal-reflection (TIR) lens for color mixing includes a body member having an outer surface and an interior open channel extending longitudinally through the body member. The body member and the interior open channel are substantially symmetric with respect to an optical axis, and the outer surface is shaped to provide total internal reflection. The body member has a first end surface region at a first end of the open channel for accommodating a light source and a second end surface region opposite the first end region. The second end surface region includes a plurality of refractive surface regions positioned around the second end region of the open channel. The lens is configured to provide projected light substantially centered with respect to the optical axis when the light source is positioned off the optical axis. In a specific embodiment, a lighting apparatus for providing centered white light includes such a lens and a plurality of light sources.

Abstract: An LED (light-emitting diode) high-power wide-angle A-19 lamp needs only a single LED emitter having multiple LEDs. The LED A-19 lamp includes a lamp envelop structure configured for transmission of light therethrough and a base structure coupled to a lower portion of the lamp envelop structure for coupling to an external power source. The dimensions of the lamp envelop structure and the base structure conform to requirement of a conventional A-19 lamp. The LED emitter includes a plurality of light-emitting diodes (LEDs) disposed in a single recess in a substrate and a single lens disposed over the LEDs and the substrate. In a specific embodiment, the emitter is configured to consume electrical power of 30 Watts or higher and to provide light distribution at 130 degrees or wider at 50% peak intensity without additional secondary optical components.

Abstract: A metal plate on a multi-die LED emitter substrate or a metal plate on a metal-core printed circuit board (MCPCB) that attaches to the emitter substrate (or both plates) can be fabricated with a number of generally radial grooves, at least some of which extend to the peripheral edge of the plate. These grooves can provide channels that allow air to escape during solder-bonding processes, reducing the size and/or total area of solder voids and thereby improving thermal transfer between the emitter and the MCPCB.

Abstract: An emitter for an LED-based lighting device has multiple groups of LEDs that are independently addressable, allowing the emitter to be tuned to a desired color bin (e.g., a specific white color) by adjusting the relative current supplied to different groups. The LED dies for the groups and a phosphor chip for each LED die are individually selected such that each LED-die/phosphor-chip combination produces light in a desired source region associated with the group to which the LED belongs. Robotic pick-and-place systems can be used to automate assembly of the emitters by selecting LED dies from a bin based on based on spectral characteristics and phosphor chips from a number of distinct phosphor chip types.

Abstract: A method for depositing a layer of phosphor-containing material on a plurality of LED dies includes disposing a template with a plurality of openings on an adhesive tape and disposing each of a plurality of LED dies in one of the plurality of openings of the template. The method also includes forming a patterned dry film photoresist layer over the template and the plurality of LED dies. The photoresist layer has a plurality of openings configured to expose a top surface of each of the LED dies. Next, a phosphor-containing material is disposed on the exposed top surface of each the LED dies. The method further includes removing the photoresist layer and the template.

Abstract: Substrates and packages for LED-based light devices can significantly improve thermal performance and provide separate electrical and thermal paths through the substrate. One substrate includes multiple electrically insulating base layers. On a top one of these layers are disposed top-side electrical contacts, including light device pads to accommodate a plurality of light devices. External electrical contacts are disposed on an exterior surface of the substrate. Electrical paths connect the top-side electrical contacts to the external electrical contacts. At least portions of some of the electrical paths are disposed between the electrically insulating base layers. The electrical paths can be arranged such that different subsets of the light device pads are addressable independently of each other. A heat dissipation plate can be formed on the bottom surface of a bottom one of the base layers.

Abstract: A light-emitting device has a light source disposed on a support. A matrix material including a dispersion of beads is disposed over the light source. The refractive index of the beads is different from the refractive index of the matrix material. The light source may include an LED. The matrix material may include a lens.

Abstract: The color of an LED-based lamp can be tuned to a desired color or color temperature. The lamp can include two or more independently addressable groups of LEDs associated with different colors or color temperatures and a total-internal-reflection (TIR) color-mixing lens to produce light of a uniform color by mixing the light from the different groups of LEDs. The color of the output light is tuned by controllably dividing an input current among the groups of LEDs. Tuning can be performed once, e.g., during manufacture, and the lamp does not require active feedback components for maintaining color temperature.

Abstract: An apparatus is used to tune the color produced by an LED-based lamp to a desired color or color temperature. To support tuning, the lamp can include two or more independently addressable groups of LEDs. Color or color temperature is tuned by controllably dividing an input current among the groups of LEDs. The apparatus determines an optimal division of the input current based on a linear interpolation between measured values of color or color temperature produced by at least two different divisions of the input current.

Abstract: A total internal reflection (TIR) lens has an integrated lamp cover adapted to a lamp of a desired form factor (e.g., PAR-38). The size and shape of the TIR lens can be adapted to optimize the light output of the lamp with little regard to the desired form factor. The integrated lamp cover can extend the front surface of the TIR lens in a direction transverse from the optical axis.

Abstract: A lens has an optical body member with a first end, a second end, and an outer surface, the outer surface being shaped to provide total internal reflection. The optical body member further has an interior open channel extending longitudinally from the first end to the second end thereof. The optical body member further has a plurality of refractive surface regions disposed in the second end thereof and around the second opening of the interior open channel. The optical body member also has a plurality of protrusions extending from the first end of the optical body member. The protrusions are disposed circumferentially around the first opening of the interior open channel and are arranged to center the optical body member and to maintain the optical body member at a predetermined position with respect to the light source. In a light apparatus having an LED emitter disposed on a substrate, the protrusions can fit into notches in the substrate.

Abstract: A lighting apparatus includes a light source having a plurality of light-emitting-diodes and a lens assembly with a lens and a lens holder. The lens includes a body member having an outer surface shaped to provide total internal reflection and an interior open channel extending longitudinally through the body member. The body member has a first end region for accommodating the light source and a second end region that includes a plurality of refractive surface regions positioned around the open channel. The lens holder has a concave interior surface shaped to accommodate the optical body member of the lens and a convex exterior surface. The holder has multiple clips for securing the lens and three or more support members extending from the exterior surface toward the first end.

Abstract: A lens assembly has a lens and a holder. The lens has an optical body member having a first end, a second end, and an outer surface. The outer surface is shaped to provide total internal reflection. The optical body member also has an interior open channel extending longitudinally from the first end to the second end thereof. The second end includes a peripheral flange that is free of curved refractive surface regions and has one or more index regions and one or more notches formed therein. The holder is a substantially cylindrical support member having a hollow interior region shaped to accommodate the optical body member. The holder also has a top rim region having one or more slots for receiving the index regions of the optical body member and one or more snap clips for fitting to the notches of the peripheral flange region of the optical body member.