LED lighting system with reflective board
View Patent ↗A light emitting apparatus ( 8 ) includes one or more light emitting chips ( 10 ) that are disposed on a printed circuit board ( 12 ) and emit light predominantly in a wavelength range between about 400 nanometers and about 470 nanometers. The printed circuit board includes: (i) an electrically insulating board ( 14 ); (ii) electrically conductive printed circuitry ( 20 ); and (iii) an electrically insulating solder mask ( 22 ) having vias ( 24 ) through which the one or more light emitting chips electrically contact the printed circuitry. The solder mask ( 22 ) has a reflectance of greater than 60% at least between about 400 nanometers and about 470 nanometers.
1. A light emitting apparatus comprising:
one or more light emitting chips emitting radiation predominantly in a wavelength range above about 470 nanometers; and
a circuit board on which the one or more light emitting chips are disposed, the circuit board including: (i) an electrically insulating board, (ii) electrically conductive circuitry, and (iii) an electrically insulating solder mask having vias through which the one or more light emitting chips electrically contact the circuitry, the solder mask having a reflectance of greater than 60% at least between about 400 nanometers and about 470 nanometers, the solder mask including an electrically insulating binder material and a filler material dispersed in the binder material, the filler material having reflectance greater than about 85% at least between about 400 nanometers and about 470 nanometers.
2. The light emitting apparatus as set forth in claim 1 , further comprising:
a housing inside of which the one or more light emitting chips and the circuit board are disposed, the housing including a phosphor arranged to be irradiated by the one or more light emitting chips, the phosphor and the circuit board being relatively arranged such that at least some of the radiation emitted by the one or more light emitting chips predominantly in a wavelength range above about 470 nanometers reflects from the phosphor onto the solder mask of the circuit board.
3. The light emitting apparatus as set forth in claim 2 , wherein the phosphor includes one or more constituents that produce fluorescence or phosphorescence that is white or a selected color or blend of colors responsive to irradiation by the one or more light emitting chips.
4. The light emitting apparatus as set forth in claim 1 , wherein the solder mask has a reflectance greater than about 85% at least between about 400 nanometers and about 470 nanometers.
5. The light emitting apparatus as set forth in claim 1 , wherein the solder mask has a reflectance greater than 60% at least between about 400 nanometers and about 740 nanometers.
6. The light emitting apparatus as set forth in claim 1 , wherein the solder mask has a reflectance greater than about 85% at least between about 400 nanometers and about 740 nanometers.
7. The light emitting apparatus as set forth in claim 1 , wherein the electrically insulating binder material is a photostabilized material.
8. The light emitting apparatus as set forth in claim 1 , wherein the binder material is one of a photostabilized epoxy and a photostabilized polyimide.
9. The light emitting apparatus as set forth in claim 1 , wherein the filler material is one of a titanium oxide and an aluminum oxide.
10. The light emitting apparatus as set forth in claim 1 , wherein the filler material is one of TiO 2 and Al 2 O 3 .
11. The light emitting apparatus as set forth in claim 1 , wherein the electrically insulating board comprises:
a metal layer; and
an electrically insulating layer disposed on at least one side of the metal layer.
12. The light emitting apparatus as set forth in claim 1 , wherein the electrically insulating board and the electrically conductive circuitry of the circuit board include a plurality of electrically insulating layers and a plurality of layers of circuitry.
13. The light emitting apparatus as set forth in claim 1 , wherein the electrically insulating solder mask comprises a multiple layer specular reflector sheet having a reflectance of greater than 60% at least between about 400 nanometers and about 470 nanometers.
14. The light emitting apparatus as set forth in claim 13 , wherein the multiple-layer specular reflector sheet comprises:
a stack of reflective dielectric layers formed of alternating layers of dielectric material having different refractive indices, different birefringence characteristics, or other dissimilar optical characteristics.
15. The light emitting apparatus as set forth in claim 13 , wherein the electrically insulating board comprises:
a metal layer; and
an electrically insulating layer disposed on at least one side of the metal layer.
16. The light emitting apparatus as set forth in claim 13 , wherein the electrically insulating board and the electrically conductive circuitry of the circuit board include a plurality of electrically insulating layers and a plurality of layers of circuitry.
17. The light emitting apparatus as set forth in claim 13 , further comprising:
a phosphor arranged to be irradiated by the one or more light emitting chips, the phosphor and the circuit board being relatively arranged such that at least some of the radiation emitted by the one or more light emitting chips predominantly in the wavelength range above about 470 nanometers reflects from the phosphor onto the solder mask of the circuit board.
18. The light emitting apparatus as set forth in claim 17 , wherein the phosphor includes one or more constituents that produce fluorescence or phosphorescence that is white or a selected color or blend of colors responsive to irradiation by the one or more light emitting chips.
19. A method for fabricating a light emitting apparatus, the method comprising:
providing an electrically insulating board including electrically conductive circuitry;
disposing an electrically insulating solder mask having a reflectance of greater than 60% at least between about 400 nanometers and about 470 nanometers on the electrically insulating board by combining constituents of a photosensitive epoxy with a reflective filler material to generate epoxy source material, the reflective filler having a reflectance greater than about 85% at least between 400 nanometers and 470 nanometers, disposing the epoxy source material on the electrically insulating board to define an epoxy solder mask layer, and photolithographically forming the vias accessing the circuitry in the epoxy solder mask layer; and
disposing one or more light emitting chips on the insulating solder mask, the one or more light emitting chips electrically contacting the circuitry through the vias in the solder mask, the one or more light emitting chips emitting radiation predominantly in a wavelength range above about 470 nanometers.
20. The method as set forth in claim 19 , wherein the disposing of an electrically insulating solder mask comprises:
combining constituents of a photosensitive epoxy with a reflective filler material to generate epoxy source material, the reflective filler having a reflectance greater than about 85% at least between 400 nanometers and 470 nanometers;
disposing the epoxy source material on the electrically insulating board to define an epoxy solder mask layer; and
photolithographically forming the vias accessing the circuitry in the epoxy solder mask layer.
21. The method as set forth in claim 20 , wherein the disposing of the epoxy source material on the electrically insulating board includes disposing the epoxy source material by one of spray coating and curtain coating.