US 12,218,477 B2
High-luminous flux laser-based white light source
Paul Rudy, Manhattan Beach, CA (US); James W. Raring, Santa Barbara, CA (US); Eric Goutain, Fremont, CA (US); Troy Trottier, Cary, NC (US); Melvin McLaurin, Santa Barbara, CA (US); James Harrison, Oro Valley, AZ (US); Sten Heikman, Goleta, CA (US); and Michael Cantore, Goleta, CA (US)
Assigned to KYOCERA SLD Laser, Inc., Goleta, CA (US)
Filed by KYOCERA SLD Laser, Inc., Goleta, CA (US)
Filed on Feb. 22, 2022, as Appl. No. 17/677,462.
Application 17/677,462 is a continuation of application No. 16/449,126, filed on Jun. 21, 2019, granted, now 11,437,774.
Application 16/449,126 is a continuation in part of application No. 16/014,010, filed on Jun. 21, 2018, granted, now 10,879,673, issued on Dec. 29, 2020.
Application 16/014,010 is a continuation in part of application No. 14/829,927, filed on Aug. 19, 2015, granted, now 10,938,182, issued on Mar. 2, 2021.
Prior Publication US 2022/0320819 A1, Oct. 6, 2022
Int. Cl. F21K 9/64 (2016.01); F21K 9/68 (2016.01); F21K 9/69 (2016.01); F21K 9/90 (2016.01); F21V 29/70 (2015.01); F21Y 115/30 (2016.01); H01S 5/00 (2006.01); H01S 5/02255 (2021.01); H01S 5/023 (2021.01); H01S 5/02325 (2021.01); H01S 5/0237 (2021.01); H01S 5/024 (2006.01); H01S 5/343 (2006.01); H01S 5/40 (2006.01); H01L 33/00 (2010.01); H01S 5/02 (2006.01); H01S 5/02345 (2021.01)
CPC H01S 5/0087 (2021.01) [F21K 9/64 (2016.08); F21K 9/68 (2016.08); F21K 9/69 (2016.08); F21K 9/90 (2013.01); F21V 29/70 (2015.01); H01S 5/02255 (2021.01); H01S 5/023 (2021.01); H01S 5/02325 (2021.01); H01S 5/0237 (2021.01); H01S 5/02469 (2013.01); H01S 5/34333 (2013.01); H01S 5/4056 (2013.01); F21Y 2115/30 (2016.08); H01L 33/0045 (2013.01); H01S 5/0216 (2013.01); H01S 5/0217 (2013.01); H01S 5/02345 (2021.01)] 20 Claims
OG exemplary drawing
 
1. A high-luminous flux laser-based white light source comprising:
a plurality of surface mount device (SMD) packages; and
a plurality of electronic board members, the plurality of SMD packages arranged in an array pattern and each electrically coupled to one of the plurality of electronic board members, each of the plurality of SMD packages including:
one or more laser diode devices each comprising a cavity member of gallium and nitrogen containing material and configured as an excitation source;
a phosphor member configured as a wavelength converter and an emitter and coupled to the one or more laser diode devices;
at least one common support member configured to support the one or more laser diode devices, the at least one common support member including one or more angled portions and a planar portion, each angled portion for supporting a laser diode device of the one or more laser diode devices, wherein an upper surface of each angled portion is at an obtuse angle relative to an upper surface of the planar portion, and the upper surface of each angled portion is arranged between relief features and is at a reflex angle relative to upper surfaces of the relief features, wherein the relief features are arranged on sides of the upper surface of each angled portion in a direction perpendicular to a length of the cavity member of the laser diode device supported by the angled portion, and wherein a width of the upper surfaces of the relief features varies in the direction perpendicular to the length of the cavity member;
an output facet configured on each of the one or more laser diode devices to output a laser beam comprised of electromagnetic radiation selected from a violet and/or a blue emission with a first wavelength ranging from 400 nm to 485 nm;
a free space, extending from the output facet on each of the one or more laser diode devices to the phosphor member, the free space having a non-guided characteristic capable of transmitting the laser beam from the output facet to an excitation surface of the phosphor member;
a range of angles of incidence between the laser beam from each of the one or more laser diode devices and the excitation surface of the phosphor member so that on average the laser beam has an off-normal incidence to the excitation surface and a beam spot is configured for a certain geometrical size and shape;
wherein the phosphor member converts a fraction of the electromagnetic radiation from each of the one or more laser diode devices to an emitted electromagnetic radiation with a second wavelength that is longer than the first wavelength; and
a reflective mode characterizing the phosphor member such that the laser beam from each of the one or more laser diode devices is incident on a beam spot area on the excitation surface of the phosphor member and a white light emission is outputted substantially from the same beam spot area, the white light emission being comprised of a mixture of wavelengths characterized by at least the emitted electromagnetic radiation with the second wavelength.