# US 9,435,493 B2 · Hybrid reflector system for lighting device > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,435,493 B2 - Document ID: US9435493B2 - Status: Granted - Kind: B2 - Application number: 12/606,377 - Filed: 2009-10-27 - Published: 2011-04-28 - Granted: 2016-09-06 - Earliest claimed: 2009-10-27 - Assignees: Cree, Inc. - Applicants: Paul Kenneth Pickard - Inventors: Paul Kenneth Pickard - Web page: https://patentgrep.com/patent/US9435493B2 ## CPC - F21K 9/23: Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings - F21K 9/233: specially adapted for generating a spot light distribution, e.g. for substitution of reflector lamps - F21V 7/0025: {Combination of two or more reflectors for a single light source (array of reflectors for a cluster of light sources F21V7/0083)} - F21V 29/505: of reflectors - F21V 29/507: of means for protecting lighting devices from damage, e.g. housings - F21V 29/74: with fins or blades - F21V 7/04: Optical design - F21V 17/164: {the parts being subjected to bending, e.g. snap joints} - F21V 29/89: Metals - F21Y 2113/17: forming a single encapsulated light source - F21Y 2115/10: Light-emitting diodes [LED] - F21K: NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR - F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR - F21Y: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED ## Abstract A hybrid reflector system for use in lighting application. The system is particularly well-suited for use with solid state light sources, such as light emitting diodes (LEDs). Embodiments of the system include a bowl-shaped outer reflector and an intermediate reflector disposed inside the bowl and proximate to the light source. The reflectors are arranged to interact with the light emitted from the source to produce a beam having desired characteristics. Some of the light passes through the system without interacting with any of the reflector surfaces. This uncontrolled light, which is already emitting in a useful direction, does not experience optical loss normally associated with one or more reflective bounces. Some of the light emanating from the source at higher angles that would not be emitted within the desired beam angle is reflected by one or both of the reflectors, redirecting that light to achieve a tighter beam. ## Claims ### Claim 1 A reflector system, comprising: a bowl-shaped outer reflector comprising a base end and an open end, said outer reflector configured to at least partially surround a light source; and an intermediate reflector inside said outer reflector said intermediate reflector shaped to define an axial hole, said intermediate reflector comprising at least one leg extending from said intermediate reflector and directly attached to said outer reflector. ### Claim 2 (depends on 1) The reflector system of claim 1, said intermediate reflector comprising a reflective interior surface shaped such that said axial hole is substantially frusto-conical. ### Claim 3 (depends on 1) The reflector system of claim 1, said intermediate reflector along a longitudinal axis running from the center of said base end to the center of said open end such that said axis runs through the center of said axial hole. ### Claim 4 (depends on 1) The reflector system of claim 1, said at least one leg comprising three legs, each of said legs extending from said intermediate reflector to said outer reflector, said legs spaced equidistantly around the exterior of said intermediate reflector. ### Claim 5 (depends on 1) The reflector system of claim 1, further comprising a lens covering said open end of said outer reflector. ### Claim 6 (depends on 5) The reflector system of claim 5, said intermediate reflector attached to said lens. ### Claim 7 (depends on 5) The reflector system of claim 5, said intermediate reflector attachable to said lens with a snap-fit mechanism. ### Claim 8 (depends on 5) The reflector system of claim 5, wherein at least a portion of said lens is roughened. ### Claim 9 (depends on 5) The reflector system of claim 5, wherein an annular section of said lens is roughened, said annular section comprising an inner and an outer radius, said inner radius a distance from the center of said lens. ### Claim 10 (depends on 5) The reflector system of claim 5, further comprising a diffusive film on said lens. ### Claim 11 (depends on 5) The reflector system of claim 5, further comprising a diffusive film on an annular section of said lens, said annular section comprising an inner and an outer radius, said inner radius a distance from the center of said lens. ### Claim 12 (depends on 5) The reflector system of claim 5, wherein at least a portion of an edge of said lens is beyond said outer reflector to allow some of the light incident proximate to said edge to emit at high angles. ### Claim 13 (depends on 1) The reflector system of claim 1, further comprising a housing shaped to surround said outer reflector without obstructing said open end. ### Claim 14 (depends on 13) The reflector system of claim 13, wherein said housing comprises a thermally conductive material, said housing in thermal contact with said outer reflector. ### Claim 15 (depends on 1) The reflector system of claim 1, said outer reflector comprising a faceted surface. ### Claim 16 (depends on 1) The reflector of claim 1, further comprising a collimating optical element disposed within said intermediate reflector at one end of said axial hole. ### Claim 17 A reflector system, comprising: a bowl-shaped outer reflector comprising a base end and an open end; and an intermediate reflector inside said outer reflector, wherein said intermediate reflector is shaped to define an axial hole, said intermediate reflector comprising at least first and second exterior surfaces, wherein said first exterior surface is angled to face said base end and said second exterior surface is angled to face said open end. ### Claim 18 (depends on 17) The reflector system of claim 17, said intermediate reflector comprising a reflective interior surface shaped such that said axial hole is substantially frusto-conical. ### Claim 19 (depends on 17) The reflector system of claim 17, further comprising a lens covering said open end of said outer reflector. ### Claim 20 (depends on 19) The reflector system of claim 19, said intermediate reflector attachable to said lens. ### Claim 21 (depends on 20) The reflector system of claim 20, wherein an annular section of said lens is roughened, said annular section comprising an inner and an outer radius, said inner radius a distance from the center of said lens. ### Claim 22 (depends on 19) The reflector system of claim 19, wherein at least a portion of said lens is roughened. ### Claim 23 (depends on 17) The reflector system of claim 17, further comprising at least one light source mounted at said base end and arranged to emit light toward said open end. ### Claim 24 A lamp device, comprising: a light source; an outer reflector comprising a base end and an open end, said light source mounted at said base end and arranged to emit light toward said open end; an intermediate reflector disposed proximate to said light source, said intermediate reflector shaped to define a hole for at least some light from said light source to pass through said intermediate reflector comprising at least on leg extending from said intermediate reflector and directly attached to said outer reflector; a housing arranged to surround said outer reflector without obstructing said open end; and a lens arranged to cover said open end. ### Claim 25 (depends on 24) The lamp device of claim 24, said intermediate reflector comprising a reflective interior surface shaped such that said axial hole has a frusto-conical shape. ### Claim 26 (depends on 24) The lamp device of claim 24, said intermediate reflector comprising at least first and second exterior surfaces, said first exterior surface angled to face said base end, said second exterior surface angled to face said open end. ### Claim 27 (depends on 24) The lamp device of claim 24, said intermediate reflector and said light source disposed along a longitudinal axis running from the center of said base end to the center of said open end such that said axis runs through the center of said hole. ### Claim 28 (depends on 24) The lamp device of claim 24, said at least one leg comprising three legs, each of said legs extending from said intermediate reflector to said outer reflector, said legs spaced equidistantly around the exterior of said intermediate reflector. ### Claim 29 (depends on 24) The lamp device of claim 24, said intermediate reflector attached to said lens. ### Claim 30 (depends on 24) The lamp device of claim 24, said intermediate reflector attachable to said lens with a snap-fit mechanism. ### Claim 31 (depends on 24) The lamp device of claim 24, wherein at least a portion of said lens is roughened. ### Claim 32 (depends on 24) The lamp device of claim 24, wherein an annular section of said lens is roughened, said annular section having an inner and an outer radius, said inner radius located a distance from the center of said lens. ### Claim 33 (depends on 24) The lamp device of claim 24, further comprising an encapsulant over said light source. ### Claim 34 (depends on 33) The lamp device of claim 33, said encapsulant comprising a diffusive material. ### Claim 35 (depends on 24) The lamp device of claim 24, said light source comprising multiple light emitting diodes (LEDs). ### Claim 36 (depends on 24) The lamp device of claim 24, said light source comprising blue and red LEDs and an encapsulant covering at least some of said LEDs and having a wavelength conversion material disposed to convert at least a portion of blue light from said blue LEDs to yellow light. ### Claim 37 (depends on 24) The lamp device of claim 24, said housing comprising a thermally conductive material, said housing in thermal contact with said light source. ### Claim 38 (depends on 24) The lamp device of claim 24, said outer reflector comprising a faceted interior surface. ### Claim 39 (depends on 24) The lamp device of claim 24, wherein said lamp device produces a light beam having a beam angle of approximately 25 degrees. ### Claim 40 (depends on 24) The lamp device of claim 24, wherein said lamp device produces a light beam having a beam angle of approximately 50 degrees. ### Claim 41 (depends on 24) The lamp device of claim 24, wherein said lamp device produces a light beam having a beam angle of approximately 10 degrees. ### Claim 42 (depends on 24) The lamp device of claim 24, further comprising a diffusive film disposed on said lens. ### Claim 43 (depends on 42) The lamp device of claim 42, further comprising an encapsulant over said light source, said encapsulant comprising a diffusive material. ### Claim 44 (depends on 42) The lamp device of claim 42, wherein said diffusive film is disposed on a surface of said lens that faces said light source. ### Claim 45 (depends on 42) The lamp device of claim 42, wherein said lamp device produces a light beam having a beam angle that is associated with the strength of said diffusive film, such that said beam angle is adjustable by replacing said diffusive film with a different diffusive film. ### Claim 46 (depends on 24) The lamp device of claim 24, further comprising a diffusive film disposed on an annular section of said lens, said annular section having an inner and an outer radius, said inner radius located a distance from the center of said lens. ### Claim 47 (depends on 24) The lamp device of claim 24, wherein said light source comprises at least one light emitting diode (LED). ### Claim 48 (depends on 24) The lamp device of claim 24, wherein at least a portion of an edge of said lens is exposed beyond said housing to allow some of the light incident proximate to said edge to emit at high angles. ### Claim 49 (depends on 24) The lamp device of claim 24, further comprising a collimating optical element disposed within said axial hole at the end of said intermediate reflector closest to said light source. ### Claim 50 A reflector system, comprising: an outer reflector comprising a base end and an open end; and an intermediate reflector at least partially inside and in a fixed relationship with said outer reflector, said intermediate reflector comprising a first end and a second end said intermediate reflector comprising at least first and second exterior surfaces, wherein said first exterior surface is angled to face said base end and said second exterior surface is angled to face said open end. ### Claim 51 (depends on 50) The reflector system of claim 50, wherein said intermediate reflector comprises a substantially frustoconical first portion and a substantially frustoconical second portion integral with said first portion; wherein a largest diameter of said first portion is equal to the largest diameter of said second portion. ### Claim 52 (depends on 51) The reflector system of claim 51, wherein the largest diameter of said first portion and the largest diameter of said second portion are at a junction between said first and second portions. ### Claim 53 (depends on 50) The reflector system of claim 50, wherein said intermediate reflector is shaped to define an axial hole. ### Claim 54 (depends on 53) The reflector system of claim 53, wherein said axial hole is substantially frustoconical from said first end to said second end. ### Claim 55 (depends on 50) The reflector system of claim 50, wherein said intermediate reflector comprises first and second portions; wherein the largest width of said first portion is equal to the largest width of said second portion. ### Claim 56 (depends on 50) The reflector system of claim 50, further comprising one or more legs connecting said intermediate reflector to said outer reflector. ### Claim 57 (depends on 56) The reflector system of claim 56, wherein said intermediate reflector comprises first and second portions; wherein said one or more legs are connected to only one of said first and second portions. ### Claim 58 (depends on 57) The reflector system of claim 57, wherein said legs are connected to the one of said first and second portions nearer said open end. ### Claim 59 (depends on 57) The reflector system of claim 57, wherein said intermediate reflector comprises first and second portions; wherein said one or more legs are connected to said intermediate reflector at a junction between said first and second portions. ### Claim 60 (depends on 50) The reflector system of claim 50, wherein said outer reflector is bowl-shaped or substantially frustoconical.