Manufacturing and measurement of freeform optics

Methods for fabricating light emitting diode (LED) chips comprising providing a plurality of LEDs typically on a substrate. Pedestals are deposited on the LEDs with each of the pedestals in electrical contact with one of the LEDs. A coating is formed over the LEDs with the coating burying at least some of the pedestals. The coating is then planarized to expose at least some of the buried pedestals while leaving at least some of said coating on said LEDs. The exposed pedestals can then be contacted such as by wire bonds. The present invention discloses similar methods used for fabricating LED chips having LEDs that are flip-chip bonded on a carrier substrate and for fabricating other semiconductor devices. LED chip wafers and LED chips are also disclosed that are fabricated using the disclosed methods.

Wafer level phosphor coating method and devices fabricated utilizing method

A method for manufacturing an apparatus and the apparatus being configured to convert a first distribution of an input radiation to a second distribution of output radiation. The method consists of the steps of generating a two-dimensional representation of at least three active optical surfaces of an optical device including calculating a segment of a first surface based on edge ray sets as a first generalized Cartesian oval, calculating a segment of an entry surface based on the edge ray set as a second generalized Cartesian oval, calculating a segment of a second surface based on the edge ray set as a third generalized Cartesian oval, and successively repeating the steps of calculating the segment of the first surface and calculating the segment of the second surface in a direction towards a source, and rotationally sweeping the two-dimensional representation about a central axis providing a three-dimensional representation of the optical device.

Compact folded-optics illumination lens

In a lighting package, a printed circuit board supports at least one light emitting die. A light transmissive cover is disposed over the at least one light emitting die. A phosphor is disposed on or inside of the light transmissive dome-shaped cover. The phosphor outputs converted light responsive to irradiation by the at least one light emitting die. An encapsulant substantially fills an interior volume defined by the light-transmissive cover and the printed circuit board.

Light emitting diode component

Light-emitting quantum dot films, quantum dot lighting devices, and quantum dot-based backlight units are provided. Related compositions, components, and methods are also described. Improved quantum dot encapsulation and matrix materials are provided. Quantum dot films with protective barriers are described. High-efficiency, high brightness, and high-color purity quantum dot-based lighting devices are also included, as well as methods for improving efficiency and optical characteristics in quantum dot-based lighting devices.

Quantum Dot Films, Lighting Devices, and Lighting Methods

An optical manifold for efficiently combining a plurality of LED outputs into a single, substantially homogeneous output, in a small, cost-effective package. The optical manifolds can be used to combine multiple LEDs of the same color and provide a high intensity output aperture with very high uniformity and sharp borders, or they can be used to generate a multiwavelength output, such as red, green, and due LEDs that are combined to generate white light. Embodiments are also disclosed that use a single or multiple LEDs and a remote phosphor and an intermediate wavelength-selective filter arranged so that backscattered photoluminescence is recycled to boost the luminance and flux of the output aperture. The optical manifolds are designed to alleviate substantial luminance inhomogeneities inherent to LEDs. The optical manifold utilizes principles of non-imaging optics to transform light and provide directed, substantially uniform light sources.

Optical manifold for light-emitting diodes

The simultaneous multiple surface (SMS) method in 3-D geometry is presented. Given two orthotomic input ray bundles and another two orthotomic output ray bundles, the method provides an optical system with two free-form surfaces that deflects the rays of the input bundles into the rays of the corresponding output bundles and vice versa. In nonimaging applications, the method enables controlling the light emitted by an extended light source much better than single free-form-surface designs, and also enables the optics contour to be shaped without efficiency losses. The method is also expected to find applications in imaging optics.

Simultaneous multiple surface optical design method in three dimensions

An optical device for coupling the luminous output of a light-emitting diode (LED) to a predominantly spherical pattern comprises a transfer section that receives the LED's light within it and an ejector positioned adjacent the transfer section to receive light from the transfer section and spread the light generally spherically. A base of the transfer section is optically aligned and/or coupled to the LED so that the LED's light enters the transfer section. The transfer section can comprises a compound elliptic concentrator operating via total internal reflection. The ejector section can have a variety of shapes, and can have diffusive features on its surface as well, including a phosphor coating. The transfer section can in some implementations be polygonal, V-grooved, faceted and other configurations.

Optical device for LED-based lamp

A highly efficient optical device comprises two opposing active non-spherical optical surfaces defined by a two-dimensional representation that is symmetrically extended to provide a three-dimensional device. A focal area, spaced apart from the optical surface and non-contiguous therewith, is defined by the two opposing active optical surfaces. The active optical surfaces each have a continuous second derivative, and the optical surfaces are defined by a polynomial with an order at least about twenty. The optical device may comprise a transparent dielectric core, and the optical surfaces may be formed on the core. A receiver may be situated at the focal area to provide a concentrator. An extended light source such as an LED may be situated at the focal area, to provide a collimator. Faceted embodiments can provide a low aspect optical device. In some embodiments a diffuser may be used to transform incident radiation into a predetermined shape.

High efficiency non-imaging optics

The present embodiments provide methods and apparatuses for providing prescribed illumination. Some embodiments provide lenses (30, 40) that include a two-dimensional beam-forming lens-profile where the profile acts to deflect light rays (38, 46) from a light source (37, 61) into a relatively narrow output beam (47). A zone of higher refractive index than that of the area outside the profile is enclosed where the higher refractive-index zone admits the light rays, a transverse axis of revolution (34, 42) is further included and extends transversely across and outside of the lens-profile so that the transverse axis extends generally laterally with respect to a luminous centroid-direction of the output beam. The lens further includes a surface of revolution formed by circularly sweeping the lens-profile about the axis .of revolution forming a circumferential beam from the output beam emitted by said surface of revolution.

Waqidi Falicoff

Papers

Optical manifold for light-emitting diodes

Simultaneous multiple surface optical design method in three dimensions

Optical device for LED-based lamp

High efficiency non-imaging optics

Circumferentially emitting luminaires and lens elements formed by transverse-axis profile-sweeps