SOLID-STATE LINEAR LIGHTING ARRANGEMENTS INCLUDING LIGHT EMITTING PHOSPHOR
A method is described for manufacturing an LED lamp module, where the individual LEDs in the lamp module do not include a conventional package structure and/or integrated encapsulation on the individual LEDs. The lamp module includes a co-extruded component, the co-extruded component comprising an elongate lens and a layer of photoluminescent material. The elongate lens is for shaping light emitted from the lamp and comprises an elongate interior cavity. The layer of a photoluminescent material is located on an interior wall of the elongate interior cavity. An optical medium is provided as part of the manufacturing process for the lamp module, where the optical medium surrounds the LEDs in an array of LEDs. The optical medium can be co-extruded over the LEDs. In addition, a liquid optical medium can be applied in the assembly process to remove air interfaces between the LEDs and component.
1 . A method of fabricating a lamp module, comprising extruding an elongated wavelength conversion component onto an array of LEDs, wherein the elongated wavelength conversion component comprises a photoluminescent wavelength conversion material.
2 . The method of claim 1 , wherein the photoluminescent wavelength conversion material comprises a wavelength conversion layer of the elongated wavelength conversion component.
3 . The method of claim 2 , and further comprising co-extruding an optical component layer and an optical medium, the optical medium surrounding the individual LEDs on the array of LEDs.
4 . The method of claim 1 , wherein individual LEDs in the array of LEDs do not contain a package structure and/or wherein individual LEDs in the array of LEDs do not include integrated encapsulant over the individual LEDs.
5 . The method of claim 1 , wherein the array of LEDs comprises at least one of an array of LED dies on a flexible substrate or a chip-on-wire structure.
6 . The method of claim 3 , and comprising using multiple separate extruders to co-extrude materials of the wavelength conversion layer, the optical component layer, and the optical medium.
7 . The method of claim 7 , in which the materials operated upon by the extruders include at least one of PC-Polycarbonate, PMMA-Poly(methyl methacrylate), PET-Polyethylene Terephthalate, and thermoform plastics.
8 . The method of claim 3 , and further comprising co-extruding a light diffusive portion.
9 . A lamp module fabricated according to the method of claim 1 .
10 . A method of fabricating a lamp module, comprising:
co-extruding an elongated optical component comprising a wavelength conversion layer, an optical component layer, and an optical medium, the optical medium comprising a channel for receiving LEDs;
applying a liquid optical medium;
assembling the elongated optical component to an array of LEDs; and
at least partially curing the liquid optical medium.
11 . The method of claim 10 , and comprising applying the liquid optical medium to the LEDs.
12 . The method of claim 10 , and comprising applying the liquid optical medium to the channel.
13 . The method of claim 10 , wherein individual LEDs in the array of LEDs do not contain a package structure and/or wherein individual LEDs in the array of LEDs do not include integrated encapsulant over the individual LEDs.
14 . The method of claim 10 , wherein the elongated solid body further comprises a light diffusive portion.
15 . A lamp module fabricated according to the method of claim 10 .
16 . A method of fabricating a lamp module, comprising:
co-extruding an elongated optical component comprising a wavelength conversion layer and an optical component layer, wherein the elongated solid body comprises an interior chamber;
applying a liquid optical medium to the interior chamber;
assembling the elongated optical component to an array of LEDs; and
curing the liquid optical medium.
17 . The method of claim 16 , wherein individual LEDs in the array of LEDs do not contain a package structure and/or wherein individual LEDs in the array of LEDs do not include integrated encapsulant over the individual LEDs.
18 . The method of claim 16 , wherein the elongated solid body further comprises a light diffusive portion.
19 . A lamp module fabricated according to the method of claim 16 .