Abstract A lamp construction in which a lens is positioned with respect to a light-emitting diode element so as to shape the light beam in a desired pattern. An epoxy material, having an index of refraction greater than unity, is placed over the diode element and is provided with a convex meniscus curved surface so as to direct the emitted light toward the lens. The efficiency of the lamp is thus increased by a two-step process: first, the epoxy material causes an increase in the critical angle of the lightemitting diode whereby a greater amount of light is emitted; and, second, the shaped epoxy directs a major amount of the emitted light toward the lens. The invention is economically manufactured, by applying the epoxy in liquid form over the diode element whereupon it hardens and naturally assumes the desired convex meniscus curvature.
A method of making a solid state lamp assembly, comprising the steps of attaching a substantially flat solid state lightemitting element onto a substantially flat surface of a support member, applying a hardening-type light-transmitting material in liquid form over said light-emitting element and permitting said material to harden, the quantity of said material being such that upon hardening it naturally assumes a thin lens having a convex meniscus outer curvature over said light-emitting element with the outer edge of the material lying on said substantially flat surface of the support member around said light-emitting element, and positioning a lens element over, and in spaced axial alignment with respect to, said convex meniscus outer curvature of the light-transmitting material.
Claim 2
Independent Claim
118 words
A method of making a solid state lamp assembly, comprising the steps of attaching a substantially flat solid state lightemitting element onto a substantially flat surface of a support member, applying a hardening-type light-transmitting material in liquid form over said light-emitting element and permitting said material to harden, the quantity of said material being such that upon hardening it naturally assumes a thin lens having a convex meniscus outer curvature over said light-emitting element with the outer edge of the material lying on said substantially flat surface of the support member around said light-emitting element, and positioning a lens element over, and in spaced axial alignment with respect to, said convex meniscus outer curvature of the light-transmitting material.
Claim 3
Dependent Claim
24 words
A method as claimed in claim 1, in which said light-transmitting material is an epoxy material having an index of refraction greater than unity.