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Although the light-emitting diode (LED) has revolutionized lighting, the non-uniformity of its correlated color temperature (CCT) still remains a major concern. In this context, to improve the light distribution performance of remote phosphor LED lamps, we employ a micropatterned array (MPA) optical film fabricated using a low-cost molding process. The parameters of the MPA, including different installation configurations, positioning, and diameters, are optimized by combining the finite-difference time-domain and ray-tracing methods. Results show that the sample with the upward-facing convex-cone MPA film that has a diameter of half of that of the remote phosphor glass, and is tightly affixed to the inward surface of the remote phosphor glass renders a superior light distribution performance. When compared with the case in which no MPA film is used, the deviation of the CCT distribution decreases from 1033 K to 223 K, and the corresponding output power of the sample is an acceptable level of 85.6%. We perform experiments to verify our simulation results, and the two sets of results exhibit a close agreement. We believe that our approach can be used to optimize MPA films for various lighting applications.

Improving LED CCT uniformity using micropatterned films optimized by combining ray tracing and FDTD methods