Solid state lighting devices having improved color uniformity and associated methods
Solid state lighting (SSL) devices and methods of manufacturing SSL devices are disclosed herein. In one embodiment, an SSL device comprises a support having a surface and a solid state emitter (SSE) at the surface of the support. The SSE can emit a first light propagating along a plurality of first vectors. The SSL device can further include a converter material over at least a portion of the SSE. The converter material can emit a second light propagating along a plurality of second vectors. Additionally, the SSL device can include a lens over the SSE and the converter material. The lens can include a plurality of diffusion features that change the direction of the first light and the second light such that the first and second lights blend together as they exit the lens. The SSL device can emit a substantially uniform color of light.
1. A method of manufacturing a solid state lighting (SSL) device, comprising:
positioning a solid state emitter (SSE) on a surface of a support having a center line axis projecting normal to the surface, wherein the SSE is configured to emit a first light along a plurality of first vectors;
positioning a first lens over the SSE;
covering the SSE and the first lens with a converter material configured to emit a second light along a plurality of second vectors; and
positioning a second lens over the SSE, the first lens, and the converter material, the second lens having a plurality of diffusion features that are formed in a random pattern, wherein the diffusion features of the second lens are configured to change directions of the first and second vectors as the first and second vectors exit the second lens such that the first light and the second light blend together, and wherein:
the second lens is large enough relative to the SSE such that the SSE functions effectively as a point source; and
the diffusion features comprise different angles relative to the SSE such that the second light propagating along the second vectors at an emission angle θ changes direction away from the center line axis and intersects with the first light propagating along the first vectors.
2. The method of claim 1 wherein positioning the second lens comprises at least one of injection molding and overmolding the second lens over the SSE, the first lens, and the converter material.
3. The method of claim 1 wherein positioning the second lens comprises:
forming the second lens separately from the SSE; and
attaching the second lens at the surface of the support after the second lens is formed.
4. The method of claim 1 wherein the diffusion features of the second lens include at least one of dimples, protrusions, grooves, or ridges.
5. The method of claim 1 wherein changing the direction of the first and second vectors with the diffusion features comprises changing the direction of the first and second vectors in at least one of a random pattern and an irregular pattern.
6. The method of claim 1 wherein positioning the second lens comprises:
forming a base portion of the second lens, the base portion being proximate to the surface of the support, wherein the base portion has a generally circular shape and the second lens has a dome-like shape.
7. The method of claim 1 wherein positioning the second lens comprises:
forming a base portion of the second lens, the base portion being proximate to the surface of the support, wherein the base portion has a shape at least generally corresponding to a shape of the SSE on the surface of the support.
8. The method of claim 1 , wherein the second lens has a dome-like shape.
9. The method of claim 1 , wherein an exterior surface of the second lens has an irregular or erratic complex curvature.
10. A method of manufacturing a solid state lighting (SSL) device, comprising:
positioning a solid state emitter (SSE) on a surface of a support having a center line axis projecting normal to the surface, wherein the SSE is configured to emit a first light along a plurality of first vectors;
positioning a first lens over the SSE;
covering the SSE and the first lens with a converter material configured to emit a second light along a plurality of second vectors; and
positioning a second lens over the SSE, the first lens, and the converter material the second lens having a plurality of diffusion features that are formed in a random pattern, wherein the diffusion features of the second lens are configured to change directions of the first and second vectors as the first and second vectors exit the second lens such that the first light and the second light blend together, and wherein:
the second lens is large enough relative to the SSE such that the SSE functions effectively as a point source; and
the diffusion features comprise different angles relative to the SSE such that the first light propagating along the first vectors at an emission angle θ changes direction toward the center line axis and intersects with the second light propagating along the second vectors.
11. A method of manufacturing a solid state lighting (SSL) device, comprising:
positioning a solid state emitter (SSE) on a surface of a support having a center line axis projecting normal to the surface, wherein the SSE is configured to emit a first light along a plurality of first vectors;
positioning a first lens over the SSE;
covering the SSE and the first lens with a converter material configured to emit a second light along a plurality of second vectors; and
positioning a second lens over the SSE, the first lens, and the converter material, the second lens having a plurality of diffusion features that are formed in a random pattern, wherein the diffusion features of the second lens are configured to randomly change directions of the first and second vectors as the first and second vectors exit the second lens such that the first light intersects the second light, and wherein:
the second lens is large enough relative to the SSE such that the SSE functions effectively as a point source; and
the diffusion features comprise different angles relative to the SSE such that first light along the first vectors at an emission angle θ changes direction toward the center line axis to intersect with the second light along the second vectors.
12. A method of manufacturing a solid state lighting (SSL) device, comprising:
positioning a solid state emitter (SSE) on a surface of a support having a center line axis projecting normal to the surface, wherein the SSE is configured to emit a first light along a plurality of first vectors;
positioning a first lens over the SSE;
covering the SSE and the first lens with a converter material configured to emit a second light along a plurality of second vectors; and
positioning a second lens over the SSE, the first lens, and the converter material, the second lens having a plurality of diffusion features that are formed in a random pattern, wherein the diffusion features of the second lens are configured to randomly change directions of the first and second vectors as the first and second vectors exit the second lens such that the first light intersects the second light and wherein:
the second lens is large enough relative to the SSE such that the SSE functions effectively as a point source; and
the diffusion features comprise different angles relative to the SSE such that the first light along the first vectors at an emission angle θ changes direction toward the center line axis to intersect with the first light along the first vectors at another emission angle that is less than the emission angle θ.