(12) United States Patent
`Luk
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 7,152,996 B2
`Dec. 26, 2006
`
`US007152996B2
`
`(54)
`
`(75)
`
`(73)
`
`DIODE LIGHTING SYSTEM
`
`Inventor John F. Luk, Flushing, NY (US)
`
`Assignee: Altman Stage Lighting Co., Inc.,
`Yonkers, NY (US)
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 950 days.
`
`(21)
`
`(22)
`
`(65)
`
`(51)
`
`(52)
`
`(58)
`
`(56)
`
`Appl. No.:
`
`09/845,073
`
`Filed:
`
`Apr. 27, 2001
`
`Prior Publication Data
`
`US 2002/0181231 A1
`
`Dec. 5, 2002
`
`Int. Cl.
`F21 V 5/00
`
`US. Cl. .................... ..
`
`(2006.01)
`362/240; 362/800; 362/227;
`362/238; 362/11
`Field of Classi?cation Search .............. .. 362/241,
`362/247, 245, 240,331,277, 319, 227, 11,
`362/244, 660, 252, 800, 238; 428/5158;
`340/815.45, 241, 247,245,240, 331,
`219
`See application ?le for complete search history.
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`4,654,629 A
`4,826,269 A
`4,893,223 A *
`
`3/1987 BoZos et al.
`5/1989 Stripper et al.
`1/1990 Arnold ..................... .. 362/252
`
`5,038,258 A *
`8/1991 Koch et al. . . . . .
`. . . .. 362/237
`5,580,163 A * 12/1996 Johnson, II ............... .. 362/285
`5,673,995 A 10/1997 Seguee
`5,690,417 A * 11/1997 Polidor et al. ............ .. 362/244
`5,752,766 A
`5/1998 Bailey
`5,838,247 A * 11/1998 Bladowski ........... .. 340/815.45
`5,890,794 A
`4/1999 Abate et a1.
`
`6,033,087 A
`6,582,090 B1 *
`2002/0048170 A1 *
`
`3/2000 Shoos et al.
`6/2003 Coots et a1. ................ .. 362/11
`4/2002 Momot et al. ............ .. 362/244
`
`OTHER PUBLICATIONS
`
`GELcoreLLC V GE Lightng The Essence of Light Order NO. and
`Encore 70852 Corp.
`Nichia Cororation Light Catalog No. 990610K Emitting Diode
`Product Guide.
`LumiLeds JV Philips Press Release Feb. 9, 2000 Lilghting Lighting
`and Agilent Technologies.
`* cited by examiner
`
`Primary ExamineriSandra O’Shea
`Assistant ExamineriAnabel Ton
`(74) Attorney, Agent, or FirmiMyron Greenspan, Esq.;
`Lackenbach Siegel, LLP
`
`(57)
`
`ABSTRACT
`
`A lighting system for stage, theatrical and architectural
`lighting, comprising a frame for supporting a plurality of
`light emitting diodes. The diodes are mounted to the frame
`so that each diode is both secured to the frame and also
`simultaneously positioned wherein each discrete diode light
`beam is directed to a prescribed rcmotc focal point (target
`Zone) and thereupon directed to a predetermined illumina
`tion area. Electrical power for transmitting and controlling
`electrical voltage to light emitting diodes by electrical
`circuitry integral with the frame. The frame can be con?g
`ured as any hollow volume such a cone, a semi-ellipse, and
`a semi-sphere or can be con?gured as planar. Flexible blanks
`having apertures and pads for electrical connections can be
`used to construct rigid frames. An imaging gate a collimat
`ing lens and a focusing lens can be interposed between the
`frame and the illumination area. The frame can also be a
`sandwich frame having positive and negative electrically
`conductive layers interposed between layers of biasable
`insulating foam.
`
`105 Claims, 31 Drawing Sheets
`
`7
`
`/
`/
`/-98
`’
`
`/
`
`/
`/
`
`Z
`
`94*)
`
`4
`/
`
`4
`
`A
`
`§ \
`84 m
`5 Q
`z
`
`I
`
`96
`
`78
`76/
`
`
`
`Page 1 of 63
`
`PHILIPS EXHIBIT 2006
`WAC v. PHILIPS
`IPR2016-01455
`
`

`
`U.S. Patent
`U.S. Patent
`
`Dec. 26, 2006
`Dec. 26,2006
`
`Sheet 1 6f 31
`Sheet 1 of 31
`
`US 7,152,996 B2
`US 7,152,996 B2
`
`FIG. 1A
`
`Page 2 of 63
`
`
`
`Page 2 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 2 6f 31
`
`US 7,152,996 B2
`
`FIGS
`
`24
`
`
`
`Page 3 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 3 of 31
`
`US 7,152,996 B2
`
`Page 4 of 63
`
`
`
`Page 4 of 63
`
`

`
`U.S. Patent
`U.S. Patent
`
`Dec. 26, 2006
`Dec. 26,2006
`
`Sheet 4 6f 31
`Sheet 4 of 31
`
`US 7,152,996 B2
`US 7,152,996 B2
`
`A
`
`wn
`
`I
`
`NM
`
`NN
`
`8 my
`
`mm
`
`Page 5 of 63
`
`
`
`Page 5 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 5 6f 31
`
`US 7,152,996 B2
`
`/
`
`E266 \
`
`53 \
`
`//////
`
`////////////,
`
`50
`./
`/
`
`52:
`
`I
`
`v///////////
`
`
`
`Page 6 of 63
`
`

`
`U.S. Patent
`U.S. Patent
`
`Dec. 26, 2006
`Dec. 26,2006
`
`Sheet 6 6f 31
`Sheet 6 of 31
`
`US 7,152,996 B2
`US 7,152,996 B2
`
`.u.N
`
`o6...3
`
`,..\ImK\7%6“omsmm§
`m».\\M3Wnma..M,..NW.\mm,W._
`
`k\\\\\\\\\\\\ \\\\\\\\\\\
`V\\
`
`/“mu.\.
`
`Page 7 of 63
`
`
`
`Page 7 of 63
`
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 7 of 31
`
`US 7,152,996 B2
`
`.
`
`A
`
`104B
`
`F|G.1O
`
`‘\l|I//
`5
`
`132
`
`V//,?§<§k\\\\\\|||IIIIIIAI§§?7/%
`
`135
`
`A
`
`F’/////////III/////////1.
`
`VP
`
`’)‘-
`
`128
`
`7/////////I////I//////4
`
`
`
`Page 8 of 63
`
`
`
`Page 8 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 8 6f 31
`
`US 7,152,996 B2
`
`FIGM
`
`143
`
`144
`
`146
`
`
`
`Page 9 of 63
`
`

`
`U.S. Patent
`U.S. Patent
`
`Dec. 26, 2006
`Dec. 26,2006
`
`Sheet 9 6f 31
`Sheet 9 of 31
`
`US 7,152,996 B2
`US 7,152,996 B2
`
`F|G.12A
`
`_
`«»
`
`\
`
`mic?
`
`gull
`O
`:2 MIII
`9, mil
`— ;.:\\\|III
`1;‘
`
`
`
`Page 10 of 63
`
`
`
`Page 10 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 10 0f 31
`
`US 7,152,996 B2
`
`
`
` ___ » H m _ \ _ m o w 0 NM : \
`
`. 0o . Nd
`
`yo _ . JG ,_ 3 mi ow? N2
`
`I. E
`
`F )x?vumn?k 3;
`
`IIIEII',
`
`
`
`Tlll 3|.‘
`
`
`
` m8 @1 H Tl‘ QNIIII"
`
`. .3, ,
`
`#Q
`
`
`
`w: Q12:
`
`81\ . 2
`
`+ , . i
`
`
`
`Page 11 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 11 6131
`
`US 7,152,996 B2
`
`I/
`/'
`
`l 156
`1/‘
`
`I
`
`14-0
`
`154
`142
`
`D 1
`
`l
`
`13
`
`l
`
`I
`I
`
`15
`l
`l
`I/
`1/
`1 0
`143
`I/
`I,
`148/ / / /,I
`150, / /
`
`I
`
`"1
`
`146
`
`152
`
`' 7 .5°
`6;9.4°
`ANGLE x
`
`81°
`85.9°
`
`84.4°
`I
`, 82.1°
`79.9
`76. °
`
`FIGJZC
`
`
`
`Page 12 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 12 6f 31
`
`US 7,152,996 B2
`
`
`
`745 ANGLE Y
`
`N
`
`
`
`Page 13 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 13 of 31
`
`US 7,152,996 B2
`
`00
`
`00
`
`0000000000000
`
`0000000000000
`
`Page 14 of 63
`
`
`
`Page 14 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 14 of 31
`
`US 7,152,996 B2
`
`V\“m““mm
`
`\\\\\\\\\\\\\\\X‘.
`
`Page 15 of 63
`
`
`
`Page 15 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 15 of 31
`
`US 7,152,996 B2
`
`Wmm““ m“
`
`C
`
`\\\\\\\\\\\\\\\
`
`Page 16 of 63
`
`
`
`Page 16 of 63
`
`

`
`U.S. Patent
`U.S. Patent
`
`Dec. 26, 2006
`Dec. 26,2006
`
`Sheet 16 of 31
`Sheet 16 0f 31
`
`US 7,152,996 B2
`US 7,152,996 B2
`
`Page 17 of 63
`
`
`
`Page 17 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 17 6f 31
`
`US 7,152,996 B2
`
`
`
`mw? .
`
`8», . V . -
`
`<8», on»,
`
`8N N m //
`8% in \ m8
`- “awn \\\\,\,\\\wn \.\ , wink
`
`
`
`
`
`“awn l \\\..uunuummuww\.w\w\\ //
`
`
`
`x], a, \
`
`
`
` 0PM 2n :3 X\\
`
`
`
`
`
`8m m5
`
`6
`
`5m.
`
`an \an a,
`
`
`. . NE 6.0,
`8n 1 NM | N; \Xm,Mn 3n \\
`
`. . \ x
`
`Z w, \
`.i m \
`“ \6 \ Non \ “ 6
`Sn \ x
`m2 x // x 3m // m
`m
`
`
`
`_ - w
`
`
`
`Page 18 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 18 6f 31
`
`US 7,152,996 B2
`
`moon
`
`‘I’
`
`I
`
`‘I
`I
`
`moon
`
`comm
`
`
`
`00mm moon <owh.
`
`Q», L
`in, Q»,
`
`won
`
`own
`
`Nwn
`
`8n _/
`OB
`
`WWW. n
`S», §MR
`
`own
`
`wwn
`
`n\\\\\\\\\\\\\\\\\\\\\\\\‘
`
`PI
`
`O
`
`93
`\ \/ \
`
`\\\\\_\\\\\\\\\\\\§
`& \\\\\\\\\\\\\\
`
`
`
`Page 19 of 63
`
`

`
`U.S. Patent
`
`Dec. 26, 2006
`
`Sheet 19 6f 31
`
`US 7,152,996 B2
`
`3 @ @ t»)
`
`69% ‘2,6
`téééghwlkgg
`
`~, @>@ @
`
`4
`
`1/
`
`394
`
`
`
`Page 20 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 20 of 31
`
`US 7,152,996 B2
`
`Page 21 of 63
`
`
`
`Page 21 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 21 of 31
`
`US 7,152,996 B2
`
`4
`
`4 O
`
`'14
`
`\\\‘\\\\\\\\\\\‘\\\\‘k\\\\\\\\\\\\ ‘
`7
`‘ TIIJVJZVIIIIIIIATII.VIIIIIIIIIIII4 ‘
`\\\‘\\\\\\\\\\\\\\\\\\\\\\\\\\‘\
`A
`
`N
`
`3NV
`
`\ \‘
`
`x\\\\\\\\\\\
`
`?_,.—
`J
`
`A L
`
`K 3
`
`.
`
`.
`
`K\\\\\\\\\\‘
`
`IXIIIIWAW
`L I‘
`
`450432E
`
`<r<-<1‘
`
`.
`
`436
`
`<(
`
`V
`P’)
`<'
`
`F|G.2O
`
`<'
`V!’
`V‘
`
`(\l
`V?
`V
`
`\\\II
`
`~'II.4'. 1'4 5 VIIIII
`
`2
`
`<-
`
`454
`
`8<
`
`'
`<-
`
`,
`
`456
`
`'llIIlIllIl4|
`
`452
`
`(D
`<'
`4
`
`M.
`
`°°l
`
`(D
`LO
`
`Page 22 of 63
`
`
`
`Page 22 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 22 of 31
`
`US 7,152,996 B2
`
`.0
`
`(O
`
`<12
`
`<'
`
`is
`
`,<3
`
`‘*
`
`I-_|G.21
`
`N
`
`3 E :2;
`
`O
`
`CD
`
`V’
`
`<'-
`
`0 - ,!.,,l!!_I|
`‘° WI
`
`VP
`
`0
`
`V‘:5 \
`
`H
`
`<1‘
`
`.\\\\‘f>’>'>’>€x\\IIllII1;'><,’>T\,’>‘x\\‘
`
`S
`\y
`\V
`
`48
`
`48
`
`ZIIIIIIIIIII
`
`VIIIIIIIIIIJ
`
`480
`
`an
`
`493
`
`492
`
` ‘
`
`494
`
`00'
`"
`
`Page 23 of 63
`
`
`
`Page 23 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 23 of 31
`
`US 7,152,996 B2
`
`Page 24 of 63
`
`
`
`Page 24 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 24 of 31
`
`US 7,152,996 B2
`
`Page 25 of 63
`
`
`
`Page 25 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 25 of 31
`
`US 7,152,996 B2
`
`Page 26 of 63
`
`
`
`Page 26 of 63
`
`

`
`Sheet 26 of 31
`
`US 7 152 996 B2
`
`552E
`
`1
`
`\\\
`
`»\w
`
`586
`
`«V
`
`566
`
`574A
`
`560A
`
`600A
`
`601A
`
`596
`
`5628
`
`5608
`
`BOOB
`
`601B
`
`/\
`
`"""’§Iv17'54/K//
`vi‘!IflfiffifffifflfflBB//\2487/Hw7%.'."‘.'."“."””""v.'."".
`
`.0WmWM.63Frmw5mU.5
`:5mmIII..Awwwmmmfiw.
`
`
`
`
`Page 27 of 63
`
`
`
`Page 27 of 63
`
`
`
`
`
`

`
`US 7,152,996 B2
`
`«U
`
`3M
`
`n«EmQB
`
`1m8
`
`Sm
`
`9%
`
`LI.HmaPQMU
`
`D
`
`Mm%
`
`WNE
`
`new
`
`Page 28 of 63
`
`
`
`Page 28 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 28 of 31
`
`US 7,152,996 B2
`
`.\\\\\/
`
`/
`
`///5
`
`8
`
`9,
`
`
`
`.~uWu‘..
`
`V
`
`‘}/F4a3n5p
`Qv!\\\N\s.NA\.\N\.§NN.a.w..nA\
`«‘\\.V,/dmflseufilxxsxlxxowvlxxsvwmmwxwA1‘\\./6\
`-..-.-----.NH.
`
`//A
`/
`sv
`.9 V44/
`
`EmN8
`mam.\,////.’
`
`’//
`
`.w©
`
`Page 29 of 63
`
`
`
`Page 29 of 63
`
`
`
`
`
`
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 29 of 31
`
`US 7,152,996 B2
`
`
`
`
`
`K
`4
`
`
`.
`
`2
`’ J//C] YAVZ//Z7 / //CA7//CA7//J
`/
`<.
`<
`
`F|G.3OA7°8
`
`
`
`
`&\\\\\\\\\\\\\\\\\\\\\\\\\\\\Y
`
`
`
`.‘.\\\\\\\\\\\\\\\\‘
`
`718
`
`Page 30 of 63
`
`
`
`‘
`
`‘ ’
`If//If//If//‘
`.‘
`,6
`‘z,
`
`I
`
`'
`
`vi
`
`r
`
`I
`
`I
`
`r
`
`-
`
`y
`
`y
`
`'
`
`’111111/
`
`,'
`
`r
`
`III
`
`
`
`
`—
`—
`”11111111// CD
`"11111111 I "0111111I $11111, $11111“
`$
`V gl
`
`11111 I"0111111[ 91111 1 $1111! $1111, ’1111 1 41 11/7 ’l11111a
`
`
`
`Page 30 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 30 of 31
`
`US 7,152,996 B2
`
`Page 31 of 63
`
`
`
`Page 31 of 63
`
`

`
`U.S. Patent
`
`Dec. 26,2006
`
`Sheet 31 of 31
`
`US 7,152,996 B2
`
`Page 32 of 63
`
`
`
`Page 32 of 63
`
`

`
`1
`DIODE LIGHTING SYSTEM
`
`FIELD OF THE INVENTION
`
`US 7,152,996 B2
`
`2
`
`invention relates to light emitting diode
`The present
`illumination sources used in combination with architectural,
`theatrical and stage lighting systems.
`
`BACKGROUND OF THE INVENTION
`
`Incandescent and halogen type lamps have been widely
`used in various conventional lighting devices for the pro-
`jection of light onto a surface for illumination and for
`general illumination purposes. Such lamps depend on the
`heating of a tungsten wire filament to a high temperature and
`therefore emit light. These lamps are not energy efficient and
`they generate excessive heat.
`Illuminating light sources such as metal halide arc lamps,
`gas discharge lamps, fluorescent lamps and halogen light
`bulbs, as examples, have been widely used in various
`conventional lighting devices for the projection of light onto
`a surface for illumination. Such light sources are used in
`architectural, theatrical and stage lighting systems as well as
`in industrial applications for lighting surfaces, scenery, an
`object, or a person. These light sources are also used to
`project a sharp image of a gobo, shutter cut, or pattern onto
`a surface when such items are placed at the gate aperture of
`lighting devices somewhere between the light source and a
`lens lighting system.
`These image projection and lighting systems are typically
`called ellipsoidals. Conventional lighting systems comprise
`an ellipsoidal reflector used with a single high-intensity
`lamp, an imaging gate, and light collection lenses, including
`focusing lenses and collimating lenses. A single ellipsoidal
`reflector is used because it enhances light collection in the
`most efficient configuration known in the art of light pro-
`jection. By definition, an ellipse has two focal points. The
`curve of an ellipsoidal reflector is matched with the light
`source to produce an exact focused secondary image of the
`light source at the same distance at which it is located from
`the reflector at the opposite end. When a light source is
`placed at the primary focal point of the reflector, the ellip-
`soidal reflector reflects or redirects, the light to the second-
`ary focal point in front of the reflector. Multi-facets on the
`inside surface of the ellipsoidal reflector project the light
`beams to the secondary focal point.
`Conventional light sources have shortcomings. They gen-
`erate a large amount of heat and so consume a large amount
`of energy, with the result that lamp life is short. In addition,
`lighting systems that use the conventional
`light sources
`suffer from the excess amount of heat that is transferred to
`
`the exterior of the fixture housing. Likewise, the use of the
`incandescent filament lamps and arc lamps in conventional
`ellipsoidal projection lighting systems transfer a high degree
`of heat to the fixtures. The primary reason for this heat loss
`is that a major part of the light energy is in fact wasted as
`infrared heat energy. The use of cold mirror coated reflectors
`has helped somewhat, but these fixtures continue to have
`low energy efficiency. An additional problem with conven-
`tional
`light sources is that
`they have low resistance to
`vibration.
`
`An alternate light source is the light emitting diode
`(LED). Advancements have been made in LED technology
`and in the overall use of LEDs. LEDs have several different
`
`characteristics that set them apart from conventional light
`emitting technology. As one example, an LED used in place
`of a conventional light source will produce a cooler, longer
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`Page 33 of 63
`
`running, and more energy efficient lighting fixture. A disad-
`vantage of LEDs when compared to incandescent and halo-
`gen lamps is their relatively low illumination intensity. A
`basic characteristic of LEDs that sets them apart from
`conventional light emitting technology is that while conven-
`tional lamps radiate light into the surrounding hemisphere
`with relatively equal intensity in all directions, light emitting
`diode lamps with their substantially planar luminescent
`elements radiate high intensity light primarily in the forward
`direction resulting in only minimal quantities of light energy
`radiated to the sides. It is to be noted, however, that LEDs
`are presently manufactured with integral lenses molded into
`the diode housings just in front of the diode chip. Even with
`the lenses, however, LEDs are available only with some
`degree of beam spread, or angle. Beam spreads of a LED,
`shown in FIG. 1 herein for purposes of exposition only, vary
`according to the manufacturer generally between approxi-
`mately 5 and 70 degrees. Despite there being some degree
`of beam spread, LEDs are much more centered than con-
`ventional lamp technology. For purposes of clarity, FIG. 2
`shows a straight line representing the virtual center of a
`typical LED beam.
`The solid state design of LEDs allows them to be more
`durable and robust, and lets them withstand shock, vibration,
`frequent power cycling, and extreme temperatures. LEDs
`have an average usable life of typically 100,000 hours or
`more when they are operated within their electrical speci-
`fications. In comparison, incandescent filament lamps gen-
`erate high-intensity light for only a short time, typically a
`few hundred hours, and are very susceptible to damage from
`both shock and vibration.
`
`Red, green, and blue (RGB) LEDs are known in the art.
`It is noted that color gel filters used with conventional light
`source technology are not necessary in diode technology
`because RGB LEDs are capable of serving as a full color
`spectrum generating light source. The primary colors red,
`green, and blue of RGB LEDs can be mixed to produce the
`secondary colors cyan, yellow, magenta (CYM), and also
`white light. Mixing green and blue gives cyan, as is known
`in the art of colors. Likewise as is known in the art, mixing
`green and red gives yellow. Mixing red and blue gives
`magenta. Mixing red, green, and blue together results in
`white. Advances in light-emitting diode technology include
`the development of multi-chip and multi-LED arrays, which
`have led to brighter LEDs available in different colors. LEDs
`are available in both visible colors and infrared. In addition
`
`to red, yellow, and amber/orange, which were the first
`available colors, LEDs are also available in green, blue, and
`even white light. Clearly,
`for many applications,
`light-
`emitting diodes can compete directly with incandescent
`filament light sources.
`While incandescent filament lamps give olf the full spec-
`trum of light, LEDs can emit focused discrete beams of color
`at a variety of different angles. Color efficiency in LEDs is
`much better than it is for incandescent filament lamps. In
`order to get color from an incandescent filament lamp, a
`specific color gel or filter in that particular color spectrum
`has to be used. This can waste 90 percent and more of the
`incandescent filament lamp’s light energy. In comparison,
`LEDs deliver 100% of their energy as light and give a more
`intense colored light. This efficiency also gives LEDs the
`advantage of white light as well.
`LED lamps have been considered for many lighting
`devices because of their long life, high luminous efficiency,
`and intrinsic colors. However, their use has been limited to
`low intensity devices because individually, they emit only
`small quantities of light energy. It has not been possible to
`
`
`
`Page 33 of 63
`
`

`
`US 7,152,996 B2
`
`3
`efliciently combine a plurality of LED lamps into a single
`lighting device comprising a number of LEDs of limited size
`together capable of emitting a concentrated light beam
`meeting specific intensity, beam spread, power consump-
`tion, and size requirements that is related to large scale
`lighting arts such as architectural displays, and theatrical and
`stage productions.
`
`PRIOR ART
`
`Because LEDs generally emit only a small quantity of
`light, it is therefore necessary to use means for increasing the
`total quantity of light. Previous inventions have been devel-
`oped to overcome this problem by increasing the number of
`LEDs used, or by aiming the LEDs to a common point.
`Some patents that have addressed this problem are as
`follows:
`
`Patent Number:
`Patent Number:
`Patent Number:
`Patent Number:
`Patent Number:
`Patent Number:
`Patent Number:
`Patent Number:
`Patent Number:
`
`4,654,629
`4,826,269
`4,893,223
`5,673,995
`5,690,417
`5,752,766
`5,838,247
`5,890,794
`6,033,087
`
`Bozos et al.
`Mar. 31, 1987
`Stripper et al.
`May 2, 1989
`Arnold
`Jan. 9, 1990
`Segued
`Oct. 7, 1997
`Plodder et al.
`Nov. 25, 1997
`Bailey et al.
`May 19, 1998
`Nov. 17, 1998 Bladowski
`Apr. 06, 1999 Abate et al.
`Mar. 07, 2000
`Shoos et al.
`
`Some recent publications describe applications that have
`addressed this area of diode technology are as follows:
`1) GELcore LLC, a joint venture of GE Lighting and
`Emcore Corporation, The Essence of Light, Order No.
`70852.
`
`2) Nichia Corporation, Light Emitting Diode Product
`Guide, Cat. No. 990610K, printed May, 1999.
`3) LumiLeds Lighting, a joint venture between Philips
`Lighting and Agilent Technologies, Press Release, Feb. 9,
`2000,
`
`www.lighting.philips.com/narn/press/1999/070199a.shtml
`Today, lighting fixtures that incorporate LEDs as their
`primary light source rely on the direct light that is emitted
`from each diode. Patents that describe lighting fixtures that
`incorporate LEDs as their primary light source and rely on
`the direct light as emitted from each diode are as follows:
`U.S. Pat. No. 4,654,629 issued to Bozos et al. on Mar. 31,
`1987, utilizes a flat planar surface to mount LEDs. Such
`diodes are primarily arranged in a flat and planar array with
`the LEDs mounted in such a manner in which the beam
`
`output from each LED is perpendicular to the mounting
`plane.
`U.S. Pat. No. 5,690,417 issued to Plodder et al. on Nov.
`25, 1997, likewise describes a planar array of light emitting
`diodes.
`
`Although a planar array is the simplest of all possible
`configurations, such a lighting system is limited in that the
`number of LEDs that can be used is limited.
`
`U.S. Pat. No. 5,673,995 issued to Segued on Oct. 7, 1997,
`discloses a support element for a motor vehicle indicating
`display and the method of making it. The invention teaches
`the broad concept of mounting a plurality of LEDs along a
`curved or arcade surface.
`
`Alternatively, some inventions focus the LEDs or other
`light sources to a common point to achieve a brighter source.
`The use of a curved mounting surface, or specifically
`mounting and positioning the individual LED allows light to
`
`4
`
`be concentrated to a remote focus point. Several patents that
`disclose this construction are as follows;
`1) U.S. Pat. No. 4,826,269 issued to Stripper et al. on May
`2, 1989.
`
`2) U.S. Pat. No. 4,893,223 issued to Arnold on Jan. 9,
`1990.
`
`3) U.S. Pat. No. 6,033,087 issued to Shoos et al. on Mar.
`7, 2000.
`
`4) U.S. Pat. No. 4,654,629 issued to Bozos mentioned
`above
`
`5) U.S. Pat. No. 5.690,417 issued to Plodder et al.
`mentioned above.
`
`These inventions all focus the discrete light sources to a
`common point for the illumination of objects for close
`inspection or for small scale viewing purposes. None of the
`named prior art disclosures are applicable to large scale use
`for viewing by an audience, for example.
`Other patents that have addressed this problem are as
`follows:
`
`1) U.S. Pat. No. 5,838,247 issued to Bladowski on Nov.
`17, 1998, discloses a lamp that uses a massed arrangement
`of LEDs. The LEDs are arranged in a conical reflector that
`directs light outwardly. All the LEDs, however, are posi-
`tioned at the same angle within the reflector housing, with
`the result that the light beams come out collimated and
`normal to the front of the reflector housing. The arrangement
`of the LEDs in the Bladowski invention offers an increased
`
`array of light sources used, but the final beam output offer
`less than maximum output because the beams from the
`discrete light sources are not directed to a common focal
`point.
`2) U.S. Pat. No. 5,752,766 issued to Bailey on May 19,
`1998, discloses a focusable LED stage light. The array of
`multi-color LEDs are mounted on a flexible diaphragm-like
`support structure which may be deflected to focus a beam of
`variable colored light. This arrangement allows a user to
`focus the individual LEDs together to form a brighter beam.
`The limitation on how many light sources can be used is
`imposed by the initial mounting surface. Suflicient room
`between the light sources is required to allow for the flexing
`of the diaphragm-like support member and to prevent them
`from interfering with each other during the flexing.
`3) U.S. Pat. No. 5,890,794 issued to Abate et al. on Apr.
`6, 1999, discloses LEDs that are positioned around the
`outside circumference of a cylinder made also of a flexible
`mounting material. The beam output in this case is projected
`outwards from the outside surface of the tube instead of
`
`converging the beam outputs to a common point. Once
`again, this configuration imposes limits on the number of
`LEDs that can be utilized. Furthermore and more impor-
`tantly, the light beams do not converge together at a focal
`point.
`4) U.S. Pat. No. 6,016,038 issued to Mueller et al. on Jan.
`18, 2000, describes LED lighting systems capable of gen-
`erating light, such as for illumination and display purposes
`that
`includes a control processor to alter the brightness
`and/or color of the generated light by using pulse-width
`modulated signals.
`5) U.S. Pat. No. 6,132,859 issued to Jolly on Oct. 17,
`2000, describes a sandwich panel with conductive cores
`interposed between layers of nonconductive foam and a
`lamp connected to at least one pin having electrical leads
`connected to the conductive cores connected to a source of
`
`electrical voltage.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`Page 34 of 63
`
`
`
`Page 34 of 63
`
`

`
`US 7,152,996 B2
`
`5
`SUMMARY OF THE INVENTION
`
`invention is to
`the object of the present
`Accordingly,
`provide an illuminating device that uses substantially the
`maximum number of LEDs possible that are compactly
`arranged in close mutual proximity onto a curved surface.
`The above object is accomplished by a unique structure
`for a LED illuminating device of the present
`invention
`which includes a larger array of LEDs that are compactly
`arranged in close proximity along the inside surface of a
`substantially ellipsoidal-type housing or a housing having a
`configuration that is related to an ellipsoidal-type housing
`with the light rays from the LEDs being directed to a single
`focal region.
`It is another object of the invention to devise an arrange-
`ment for focusing a plurality of LEDs mounted on any type
`of surface into a single focal region with all the LEDs being
`directed to a single focal region.
`It is a further object of this invention to maximize the
`number of LEDs within any suitably confined volume by
`arranging the LEDs in an array on the inner surface of the
`volume so as to obtain the most efficient and brightest
`possible light output.
`It is yet another object of this invention to use an LED
`light source in combination with an imaging gate and lenses
`to create an energy efficient and longer-lasting lighting
`system.
`It is yet another object of this invention to use individual
`LED light sources mounted in a hollow volume configured
`in any of several known geometric configurations that
`efficiently direct the light beams emitted by each of the
`LEDs to a common focal point, or target zone, for the
`purpose of organizing the individual LED light sources into
`a single total LED generated light beam.
`In accordance with these and other objects that will be
`made evident
`in the course of this disclosure,
`there is
`provided a lighting system for architectural, theatrical and
`stage lighting including a frame for supporting a plurality of
`light emitting diodes (LEDs) for generating a plurality of
`substantially forward-directed light beams to a prescribed
`focal point, or target zone so that an organized diode-
`generated light beam is directed from the target zone to an
`illumination area. The diode frame can be configured as a
`hollow volume of various geometrical configurations such
`as semi-ellipsoidal shaped, cone-shaped, and semi-spherical
`shaped. The diode frame can also be planar. An imaging gate
`aperture, a collimating lens and a focusing lens can be
`included in the illumination lighting system. A flexible
`unitary housing/diode mounting frame/electrical circuit
`board can be used to construct a unitary rigid housing/diode
`mounting frame/electrical circuit board for many of the
`variously configured hollow volumes in which the LEDs are
`positioned.
`The present invention will be better understood and the
`objects and important features, other than those specifically
`set forth above, will become apparent when consideration is
`given to the following details and description, which when
`taken in conjunction with the armexed drawings, describes,
`illustrates, and shows preferred embodiments or modifica-
`tions of the present invention and what is presently consid-
`ered and believed to be the best mode of practice in the
`principles thereof.
`Unlike incandescent lamps that radiate their light into the
`surrounding hemisphere with relatively equal intensity in all
`directions, LED lamps with their substantially planar lumi-
`nescent elements, radiate high intensity light in the forward
`direction with a substantial gradient resulting in only mini-
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`6
`mal quantities of light energy radiated to the sides. The
`present invention takes advantage of the LED and incorpo-
`rates them in a new arrangement array allowing for more
`LEDs to be installed into a similarly sized space. Each LED
`is mounted to a mounting template that aims each LED so
`that the light beam emanating from each LED points to a
`common remote location, or
`target zone. This unique
`arrangement array gives rise to a more concentrated and
`much brighter light output than is attained in the known art
`of the ellipsoidal housing. When RGB LEDs are used, a
`brighter and more intense full spectrum of color can be
`obtained. This feature in combination with the ability to
`project a sharp focused pattern gives rise to a new and
`unique lighting system.
`Unlike incandescent lamps that radiate their light into the
`surrounding hemisphere with relatively equal intensity in all
`directions, LED lamps with their substantially planar lumi-
`nescent elements, radiate high intensity light substantially in
`the forward direction resulting in only minimal quantities of
`light energy being radiated to the sides. The present inven-
`tion takes advantage of this characteristic of the LED and
`incorporates it in the new arrangement array set forth above
`so as to increase and even maximize in at least one con-
`
`figuration the number of LEDs that can be installed into a
`given volume.
`As described, each LED is mounted to a housing and is
`properly aimed so that the combined light outputs all point
`to a common remote location. This unique arrangement
`array gives rise to a highly concentrated and bright light
`output
`in a more efficient manner than has been made
`possible by the prior art. When combined with an imaging
`gate and a light collimating lens that projects the diode
`generated light onto a display surface for lighting or view-
`ing, a brighter lighting system than has been know in the art
`is possible. When RGB LEDs are used, a brighter and more
`intense full spectrum of color can be obtained.
`In applications where the overall diameter of the light
`fixture is limited, as in the case of conventional ellipsoidal
`fixtures, such size restriction puts a limitation to the number
`of LEDs that can be used. Stated in another way, the total
`mass of LEDs is limited by the diameter of the standard light
`fixture. In addition, when the overall diameter of the light
`fixture is less that the overall length of the light fixture, there
`is also a limitation to the number of LEDs that can be used.
`
`The greatest number of LEDs can be achieved with a
`housing that offers the greater surface area. Such an area is
`directly related to the length of the housing compared to the
`diameter of the housing. Stated in another way, a long
`housing provides the most efficient configuration for maxi-
`mizing the number of LEDs. Besides the mentioned planar
`and conical mounting surfaces, also possible are spherical,
`parabolic, ellipsoidal, and other curved mounting surfaces.
`It is possible to compare various surface configurations to
`determine which surface will provide the greatest number of
`LEDs. Basically, the curve with the largest lateral area or
`surface area for the mounting of the LEDs will allow the
`greatest array. The surface area as herein defined is the sum
`of the areas of all of the forward facing surfaces, or faces, of
`a three-dimensional hollow volume.
`Basic mathematical calculations related to the above
`definition of the surface area for a three dimensional hollow
`
`volume with a diameter of 2x and a depth of y are as follows:
`The hypotenuse z can be derived from z2%(2+y2:
`A flat planar circular arrangement gives an area of A:Pi
`(X2)
`A semi-spherical arrangement gives a surface area of S:2
`Pi(x2).
`
`Page 35 of 63
`
`
`
`Page 35 of 63
`
`

`
`US 7,152,996 B2
`
`7
`A conical arrangement gives a surface area of S=Pi(xz).
`A semi-ellipsoidal arrangement gives a surface area of
`S=2 Pi((y/x)/2)2
`.
`Given x=1 in.; y=3 in.; z=3.162278 in. and Pi=3.141592,
`the following values are defined for this example:
`The flat planar circular arrangement gives an area of3.14
`sq. in.
`The semi-spherical arrangement gives a surface area of
`6.28 sq. in.
`The conical arrangement gives a surface area of 9.93 sq.
`Ill.
`The semi-ellipsoidal arrangement gives a surface area of
`14.14 sq. in.
`Based on the above quantitative calculations, one can
`conclude the following:
`A flat planar arrangement uses the least amount of LEDs.
`A spherical arrangement uses more LEDs.
`A conical arrangement uses even more LEDs.
`An ellipsoidal arrangement provides the greatest number
`ofLEDs.
`LEDs are available in different sizes and shapes. The
`LEDs used in the following examples are the white NSPW
`500BS Series of High Luminous Intensity lamp types avail(cid:173)
`able from Nichia Corporation, but they are readily available
`from other sources among others including GELcore LLC,
`a joint company that combines GE Lighting and Emcore
`Corporation, and LumiLeds Lighting that combines Philips
`Lighting and Hewlett Packard's Agilent Technologies.
`Using a round 5 mm diameter LED as the preferred lumi(cid:173)
`nescent light source and an overall diameter housing of 2.2
`in. with a depth of 3.0 in., the following actual number of
`LEDs were mounted with each of the configuration arrange(cid:173)
`ments to achieve the maximum possible array:
`The flat circular surface provided for 67 LEDs.
`The semi-spherical surface provided for 90 LEDs.
`The conical surface provided for 110 LEDs.
`The semi-ellipsoidal surface provided for 181 LEDs.
`A correlation between the number of light emitting diodes
`used to an expected luminous output can be developed. For
`example, each 5 mm LED used in this calculation is 40
`expected to deliver about 5.60 candela operating at