U.S. patent application number 14/714019 was filed with the patent office on 2015-09-03 for led-based illumination modules with thin color converting layers.
The applicant listed for this patent is Xicato, Inc.. Invention is credited to Gerard Harbers, Padmanabha Rao Ravilisetty.
Application Number | 20150247619 14/714019 |
Document ID | / |
Family ID | 45924996 |
Filed Date | 2015-09-03 |
United States Patent
Application |
20150247619 |
Kind Code |
A1 |
Ravilisetty; Padmanabha Rao ;
et al. |
September 3, 2015 |
LED-BASED ILLUMINATION MODULES WITH THIN COLOR CONVERTING
LAYERS
Abstract
An illumination module includes a plurality of Light Emitting
Diodes (LEDs). The illumination module may include a reflective
color converting element with a PTFE layer and a color converting
layer fixed to the PTFE layer. The color converting layer includes
phosphor particles embedded in a polymer matrix and has a thickness
that is less than five times an average diameter of the phosphor
particles. The illumination module may include a transmissive color
converting element. The color converting elements may be produced
by mixing a polymer binder with a solvent and phosphor particles to
form a homogeneous suspension of the phosphor particles. The
homogeneous suspension is applied to a surface to form an uncured
color converting layer, which is heated to vaporize the solvent.
The cured color converting layer includes the phosphor particles
suspended in the polymer binder
Inventors: |
Ravilisetty; Padmanabha Rao;
(Cupertino, CA) ; Harbers; Gerard; (Sunnyvale,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Xicato, Inc. |
San Jose |
CA |
US |
|
|
Family ID: |
45924996 |
Appl. No.: |
14/714019 |
Filed: |
May 15, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13867840 |
Apr 22, 2013 |
9033531 |
|
|
14714019 |
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|
13328974 |
Dec 16, 2011 |
8425065 |
|
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13867840 |
|
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61428691 |
Dec 30, 2010 |
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Current U.S.
Class: |
427/64 |
Current CPC
Class: |
F21V 13/08 20130101;
F21Y 2105/10 20160801; F21V 7/26 20180201; C09K 11/7774 20130101;
F21K 9/23 20160801; C09K 11/02 20130101; C09K 11/0883 20130101;
F21K 9/64 20160801; F21V 13/12 20130101; F21K 9/90 20130101; F21Y
2115/10 20160801; F21V 29/74 20150115; F21V 3/04 20130101; C09K
11/7734 20130101; F21V 9/30 20180201; F21V 13/04 20130101; F21V
3/12 20180201; F21V 7/30 20180201 |
International
Class: |
F21V 9/16 20060101
F21V009/16; C09K 11/02 20060101 C09K011/02 |
Claims
1. A method comprising: mixing a polymer binder with a solvent and
a plurality of phosphor particles to form a homogeneous suspension
of the phosphor particles; applying the homogeneous suspension to a
surface of a transparent substrate to form an uncured color
converting layer; and heating the uncured color converting layer to
vaporize the solvent to form a cured color converting layer,
wherein the cured color converting layer includes the phosphor
particles suspended in the polymer binder, and wherein a thickness
of the cured color converting layer on the transparent substrate is
less than five times an average diameter of the phosphor particles.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 13/867,840, filed Apr. 22, 2013, which is a continuation of
U.S. application Ser. No. 13/328,974, filed Dec. 16, 2011, now U.S.
Pat. No. 8,425,065, issued Apr. 23, 2013, which claims priority
under 35 USC 119 to U.S. Provisional Application No. 61/428,691,
filed Dec. 30, 2010, all of which are incorporated by reference
herein in their entireties.
TECHNICAL FIELD
[0002] The described embodiments relate to illumination modules
that include Light Emitting Diodes (LEDs).
BACKGROUND
[0003] The use of light emitting diodes in general lighting is
still limited due to limitations in light output level or flux
generated by the illumination devices. Illumination devices that
use LEDs also typically suffer from poor color quality
characterized by color point instability. The color point
instability varies over time as well as from part to part. Poor
color quality is also characterized by poor color rendering, which
is due to the spectrum produced by the LED light sources having
bands with no or little power. Further, illumination devices that
use LEDs typically have spatial and/or angular variations in the
color. Additionally, illumination devices that use LEDs are
expensive due to, among other things, the necessity of required
color control electronics and/or sensors to maintain the color
point of the light source or using only a small selection of
produced LEDs that meet the color and/or flux requirements for the
application.
[0004] Consequently, improvements to illumination device that uses
light emitting diodes as the light source are desired.
SUMMARY
[0005] An illumination module includes a plurality of Light
Emitting Diodes (LEDs). The illumination module may include a
reflective color converting element with a PTFE layer and a color
converting layer fixed to the PTFE layer. The color converting
layer includes phosphor particles embedded in a polymer matrix and
has a thickness that is less than five times an average diameter of
the phosphor particles. The illumination module may include a
transmissive color converting element. The color converting
elements may be produced by mixing a polymer binder with a solvent
and phosphor particles to form a homogeneous suspension of the
phosphor particles. The homogeneous suspension is applied to a
surface to form an uncured color converting layer, which is heated
to vaporize the solvent. The cured color converting layer includes
the phosphor particles suspended in the polymer binder
[0006] In an embodiment, an apparatus includes a light source
sub-assembly having a plurality of Light Emitting Diodes (LEDs);
and a reflective color converting element comprising a
polytetrafluoroethylene (PTFE) layer and a first color converting
layer fixed to the PTFE layer, wherein the first color converting
layer includes a plurality of phosphor particles of a first type
embedded in a polymer matrix, and wherein a thickness of the first
color converting layer is less than five times an average diameter
of the phosphor particles.
[0007] In an embodiment, an apparatus includes a light source
sub-assembly having a plurality of Light Emitting Diodes (LEDs); a
reflective color converting element comprising a
polytetrafluoroethylene (PTFE) layer and a first color converting
layer fixed to the PTFE layer, wherein the first color converting
layer includes a plurality of phosphor particles of a first type
embedded in a polymer matrix, and wherein a thickness of the first
color converting layer is less than five times an average diameter
of the phosphor particles; and a transmissive color converting
element comprising an optically transparent layer and a second
color converting layer fixed to the optically transparent layer,
wherein the second color converting layer includes a plurality of
second phosphor particles, wherein the second phosphor particles
have a peak emission wavelength of no more than 600 nanometers.
[0008] In an embodiment, an apparatus includes a plurality of Light
Emitting Diodes (LEDs); a transmissive color converting assembly
positioned to receive a light emitted from the plurality of LEDs,
the transmissive color converting assembly comprising: a first
transmissive optical element; a second transmissive optical
element; a first color converting material disposed between the
first transmissive optical element and the second transmissive
optical element; and a sealing material disposed between the first
transmissive optical element and the second transmissive optical
element that fixedly couples the first transmissive optical element
to the second transmissive optical element, wherein the first color
converting material is contained by the first transmissive optical
element and the second transmissive optical element and the sealing
material.
[0009] In an embodiment, a method includes mixing a polymer binder
with a solvent and a plurality of phosphor particles to form a
homogeneous suspension of the phosphor particles; applying the
homogeneous suspension to a surface to form an uncured color
converting layer; and heating the uncured color converting layer to
vaporize the solvent to form a cured color converting layer,
wherein the cured color converting layer includes the phosphor
particles suspended in the polymer binder, and wherein a thickness
of the cured color converting layer is less than five times an
average diameter of the phosphor particles.
[0010] Further details and embodiments and techniques are described
in the detailed description below. This summary does not define the
invention. The invention is defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1, 2, and 3 illustrate three exemplary luminaires,
including an illumination device, reflector, and light fixture.
[0012] FIG. 4 shows an exploded view illustrating components of LED
based illumination device as depicted in FIG. 1.
[0013] FIGS. 5A and 5B illustrates a perspective, cross-sectional
view of LED based illumination device as depicted in FIG. 1.
[0014] FIG. 6 is a flow chart illustrative of a method of applying
a thin layer of phosphor onto a reflective substrate.
[0015] FIG. 7 is a flow chart illustrative of a method of applying
a thin, semi-transparent color converting layer onto a transparent
substrate.
[0016] FIG. 8 is illustrative of a cross-sectional view of LED
based illumination module that includes reflective and transmissive
color converting elements coated with a thin layer of phosphor.
[0017] FIG. 9 illustrates a cross-sectional view of a portion of
LED illumination module with the transmissive color converting
element having a color converting layer with a thickness less than
five times the average diameter of phosphor particles.
[0018] FIG. 10 illustrates a cross-sectional view of a portion of
LED illumination module with the transmissive color converting
element having a color converting layer with a single layer of
phosphor particles.
[0019] FIG. 11 illustrates a cross-sectional view of a portion of
the LED illumination module with the reflective color converting
element having a color converting layer with a thickness less than
five times the average diameter of phosphor particles.
[0020] FIG. 12 illustrates a cross-sectional view of a portion of
the LED illumination module with the reflective color converting
element having a color converting layer with a single layer of
phosphor particles.
[0021] FIG. 13 illustrates a cross-sectional view of LED
illumination module with a transmissive color converting
assembly.
[0022] FIG. 14 is illustrative of a top view of transmissive color
converting assembly shown in FIG. 13.
[0023] FIG. 15 is a flow chart illustrative of a method of
enclosing a thin, semi-transparent color converting layer between
two transparent substrates and sealing the color converting layer
from the environment.
[0024] FIG. 16 illustrates a cross-sectional view of LED
illumination module with a color converting layer disposed on
transmissive layer and encapsulated with a seal element.
[0025] FIG. 17 is a flow chart illustrative of a method of
encapsulating a thin, semi-transparent color converting layer on a
transmissive substrate and sealing the color converting layer from
the environment.
[0026] FIG. 18 illustrates a cross-sectional view of LED
illumination module with a color converting layer embedded in the
surface of transmissive layer.
[0027] FIG. 19 illustrates a reflective layer of PTFE material.
DETAILED DESCRIPTION
[0028] Reference will now be made in detail to background examples
and some embodiments of the invention, examples of which are
illustrated in the accompanying drawings.
[0029] FIGS. 1, 2, and 3 illustrate three exemplary luminaires, all
labeled 150. The luminaire illustrated in FIG. 1 includes an
illumination module 100 with a rectangular form factor. The
luminaire illustrated in FIG. 2 includes an illumination module 100
with a circular form factor. The luminaire illustrated in FIG. 3
includes an illumination module 100 integrated into a retrofit lamp
device. These examples are for illustrative purposes. Examples of
illumination modules of general polygonal and elliptical shapes may
also be contemplated. Luminaire 150 includes illumination module
100, reflector 140, and light fixture 130. As depicted, light
fixture 130 includes a heat sink capability. However, light fixture
130 may include other structural and decorative elements (not
shown). Reflector 140 is mounted to illumination module 100 to
collimate or deflect light emitted from illumination module 100.
The reflector 140 may be made from a thermally conductive material,
such as a material that includes aluminum or copper and may be
thermally coupled to illumination module 100. Heat flows by
conduction through illumination module 100 and the thermally
conductive reflector 140. Heat also flows via thermal convection
over the reflector 140. Reflector 140 may be a compound parabolic
concentrator, where the concentrator is constructed of or coated
with a highly reflecting material. Optical elements, such as a
diffuser or reflector 140 may be removably coupled to illumination
module 100, e.g., by means of threads, a clamp, a twist-lock
mechanism, or other appropriate arrangement. As illustrated in FIG.
3, the reflector 140 may include sidewalls 141 and a window 142
that are optionally coated, e.g., with a wavelength converting
material, diffusing material or any other desired material.
[0030] As depicted in FIGS. 1, 2, and 3, illumination module 100 is
mounted to heat sink 130. Heat sink 130 may be made from a
thermally conductive material, such as a material that includes
aluminum or copper and may be thermally coupled to illumination
module 100. Heat flows by conduction through illumination module
100 and the thermally conductive heat sink 130. Heat also flows via
thermal convection over heat sink 130. Illumination module 100 may
be attached to heat sink 130 by way of screw threads to clamp the
illumination module 100 to the heat sink 130. To facilitate easy
removal and replacement of illumination module 100, illumination
module 100 may be removably coupled to heat sink 130, e.g., by
means of a clamp mechanism, a twist-lock mechanism, or other
appropriate arrangement. Illumination module 100 includes at least
one thermally conductive surface that is thermally coupled to heat
sink 130, e.g., directly or using thermal grease, thermal tape,
thermal pads, or thermal epoxy. For adequate cooling of the LEDs, a
thermal contact area of at least 50 square millimeters, but
preferably 100 square millimeters should be used per one watt of
electrical energy flow into the LEDs on the board. For example, in
the case when 20 LEDs are used, a 1000 to 2000 square millimeter
heatsink contact area should be used. Using a larger heat sink 130
may permit the LEDs 102 to be driven at higher power, and also
allows for different heat sink designs. For example, some designs
may exhibit a cooling capacity that is less dependent on the
orientation of the heat sink. In addition, fans or other solutions
for forced cooling may be used to remove the heat from the device.
The bottom heat sink may include an aperture so that electrical
connections can be made to the illumination module 100.
[0031] FIG. 4 illustrates an exploded view of components of LED
based illumination module 100 as depicted in FIG. 1 by way of
example. It should be understood that as defined herein an LED
based illumination module is not an LED, but is an LED light source
or fixture or component part of an LED light source or fixture. For
example, an LED based illumination module may be an LED based
replacement lamp such as depicted in FIG. 3. LED based illumination
module 100 includes one or more LED die or packaged LEDs and a
mounting board to which LED die or packaged LEDs are attached. In
one embodiment, the LEDs 102 are packaged LEDs, such as the Luxeon
Rebel manufactured by Philips Lumileds Lighting. Other types of
packaged LEDs may also be used, such as those manufactured by OSRAM
(Oslon package), Luminus Devices (USA), Cree (USA), Nichia (Japan),
or Tridonic (Austria). As defined herein, a packaged LED is an
assembly of one or more LED die that contains electrical
connections, such as wire bond connections or stud bumps, and
possibly includes an optical element and thermal, mechanical, and
electrical interfaces. The LED chip typically has a size about 1 mm
by 1 mm by 0.5 mm, but these dimensions may vary. In some
embodiments, the LEDs 102 may include multiple chips. The multiple
chips can emit light of similar or different colors, e.g., red,
green, and blue. Mounting board 104 is attached to mounting base
101 and secured in position by mounting board retaining ring 103.
Together, mounting board 104 populated by LEDs 102 and mounting
board retaining ring 103 comprise light source sub-assembly 115.
Light source sub-assembly 115 is operable to convert electrical
energy into light using LEDs 102. The light emitted from light
source sub-assembly 115 is directed to light conversion
sub-assembly 116 for color mixing and color conversion. Light
conversion sub-assembly 116 includes cavity body 105 and an output
port, which is illustrated as, but is not limited to, an output
window 108. Light conversion sub-assembly 116 optionally includes
either or both bottom reflector insert 106 and sidewall insert 107.
Output window 108, if used as the output port, is fixed to the top
of cavity body 105. In some embodiments, output window 108 may be
fixed to cavity body 105 by an adhesive. To promote heat
dissipation from the output window to cavity body 105, a thermally
conductive adhesive is desirable. The adhesive should reliably
withstand the temperature present at the interface of the output
window 108 and cavity body 105. Furthermore, it is preferable that
the adhesive either reflect or transmit as much incident light as
possible, rather than absorbing light emitted from output window
108. In one example, the combination of heat tolerance, thermal
conductivity, and optical properties of one of several adhesives
manufactured by Dow Corning (USA) (e.g., Dow Corning model number
SE4420, SE4422, SE4486, 1-4173, or SE9210), provides suitable
performance. However, other thermally conductive adhesives may also
be considered.
[0032] Either the interior sidewalls of cavity body 105 or sidewall
insert 107, when optionally placed inside cavity body 105, is
reflective so that light from LEDs 102, as well as any wavelength
converted light, is reflected within the cavity 109 until it is
transmitted through the output port, e.g., output window 108 when
mounted over light source sub-assembly 115. Bottom reflector insert
106 may optionally be placed over mounting board 104. Bottom
reflector insert 106 includes holes such that the light emitting
portion of each LED 102 is not blocked by bottom reflector insert
106. Sidewall insert 107 may optionally be placed inside cavity
body 105 such that the interior surfaces of sidewall insert 107
direct light from the LEDs 102 to the output window when cavity
body 105 is mounted over light source sub-assembly 115. Although as
depicted, the interior sidewalls of cavity body 105 are rectangular
in shape as viewed from the top of illumination module 100, other
shapes may be contemplated (e.g., clover shaped or polygonal). In
addition, the interior sidewalls of cavity body 105 may taper or
curve outward from mounting board 104 to output window 108, rather
than perpendicular to output window 108 as depicted.
[0033] Bottom reflector insert 106 and sidewall insert 107 may be
highly reflective so that light reflecting downward in the cavity
109 is reflected back generally towards the output port, e.g.,
output window 108. Additionally, inserts 106 and 107 may have a
high thermal conductivity, such that it acts as an additional heat
spreader. By way of example, the inserts 106 and 107 may be made
with a highly thermally conductive material, such as an aluminum
based material that is processed to make the material highly
reflective and durable. By way of example, a material referred to
as Miro.RTM., manufactured by Alanod, a German company, may be
used. High reflectivity may be achieved by polishing the aluminum,
or by covering the inside surface of inserts 106 and 107 with one
or more reflective coatings. Inserts 106 and 107 might
alternatively be made from a highly reflective thin material, such
as Vikuiti.TM. ESR, as sold by 3M (USA), Lumirror.TM. E60L
manufactured by Toray (Japan), or microcrystalline polyethylene
terephthalate (MCPET) such as that manufactured by Furukawa
Electric Co. Ltd. (Japan). In other examples, inserts 106 and 107
may be made from a polytetrafluoroethylene (PTFE) material. In some
examples inserts 106 and 107 may be made from a PTFE material of
one to two millimeters thick, as sold by W.L. Gore (USA) and
Berghof (Germany). In yet other embodiments, inserts 106 and 107
may be constructed from a PTFE material backed by a thin reflective
layer such as a metallic layer or a non-metallic layer such as ESR,
E60L, or MCPET. Also, highly diffuse reflective coatings can be
applied to any of sidewall insert 107, bottom reflector insert 106,
output window 108, cavity body 105, and mounting board 104. Such
coatings may include titanium dioxide (TiO2), zinc oxide (ZnO), and
barium sulfate (BaSO4) particles, or a combination of these
materials.
[0034] FIGS. 5A and 5B illustrate perspective, cross-sectional
views of LED based illumination module 100 as depicted in FIG. 1.
In this embodiment, the sidewall insert 107, output window 108, and
bottom reflector insert 106 disposed on mounting board 104 define a
light mixing cavity 109 (illustrated in FIG. 5A) in the LED based
illumination module 100. A portion of light from the LEDs 102 is
reflected within light mixing cavity 109 until it exits through
output window 108. Reflecting the light within the cavity 109 prior
to exiting the output window 108 has the effect of mixing the light
and providing a more uniform distribution of the light that is
emitted from the LED based illumination module 100.
[0035] The LEDs 102 can emit different or the same colors, either
by direct emission or by phosphor conversion, e.g., where phosphor
layers are applied to the LEDs as part of the LED package. Thus,
the illumination device 100 may use any combination of colored LEDs
102, such as red, green, blue, amber, or cyan, or the LEDs 102 may
all produce the same color light or some or all may produce white
light. For example, the LEDs 102 may all emit either blue or UV
light. In addition, the LEDs 102 may emit polarized light or
non-polarized light and LED based illumination device 100 may use
any combination of polarized or non-polarized LEDs. When used in
combination with phosphors (or other wavelength conversion means),
which may be, e.g., in or on the output window 108, applied in or
on the sidewalls of cavity body 105 such as in or on sidewall
insert 107, applied in or on bottom reflector 106, or applied to
other components placed inside the cavity (not shown), such that
the output light of the illumination device 100 has the color as
desired. The photo converting properties of the wavelength
converting materials in combination with the mixing of light within
cavity 109 results in the output port, e.g., output window 108,
emitting color converted light. By tuning the chemical and/or
physical (such as thickness and concentration) properties of the
wavelength converting materials and the geometric properties of the
coatings on the interior surfaces of cavity 109, specific color
properties of light output by output window 108 may be specified,
e.g., color point, color temperature, and color rendering index
(CRI).
[0036] Portions of cavity 109, such as the bottom reflector insert
106, sidewall insert 107, and cavity body 105, may be coated with a
wavelength converting material. FIG. 5B illustrates portions of the
sidewall insert 107 coated with a wavelength converting material.
Furthermore, portions of output window 108 may be coated with the
same or a different wavelength converting material. In addition,
portions of bottom reflector insert 106 may be coated with the same
or a different wavelength converting material. In another example
(not shown), sidewall insert 107 is omitted and the interior facing
walls of cavity body 105 may be coated with a wavelength converting
material.
[0037] By way of example, the phosphors may be chosen from the set
denoted by the following chemical formulas:
Y.sub.3Al.sub.5O.sub.12:Ce, (also known as YAG:Ce, or simply YAG)
(Y,Gd).sub.3Al.sub.5O.sub.12:Ce, CaS:Eu, SrS:Eu,
SrGa.sub.2S.sub.4:Eu, Ca.sub.3(Sc,Mg).sub.2Si.sub.3O.sub.12:Ce,
Ca.sub.3Sc.sub.2Si.sub.3O.sub.12:Ce, Ca.sub.3Sc.sub.2O.sub.4:Ce,
Ba.sub.3Si.sub.6O.sub.12N.sub.2:Eu, (Sr,Ca)AlSiN.sub.3:Eu,
CaAlSiN.sub.3:Eu, CaAlSi(ON).sub.3:Eu, Ba.sub.2SiO.sub.4:Eu,
Sr.sub.2SiO.sub.4:Eu, Ca.sub.2SiO.sub.4:Eu, CaSc.sub.2O.sub.4:Ce,
CaSi.sub.2O.sub.2N.sub.2:Eu, SrSi.sub.2O.sub.2N.sub.2:Eu,
BaSi.sub.2O.sub.2N.sub.2:Eu, Ca.sub.5(PO.sub.4).sub.3Cl:Eu,
Ba.sub.5(PO.sub.4).sub.3Cl:Eu, Cs.sub.2CaP.sub.2O.sub.7,
Cs.sub.2SrP.sub.2O.sub.7, Lu.sub.3Al.sub.5O.sub.12:Ce,
Ca.sub.8Mg(SiO.sub.4).sub.4Cl.sub.2:Eu,
Sr.sub.8Mg(SiO.sub.4).sub.4Cl.sub.2:Eu,
La.sub.3Si.sub.6N.sub.11:Ce, Y.sub.3Ga.sub.5O.sub.12:Ce,
Gd.sub.3Ga.sub.5O.sub.12:Ce, Tb.sub.3Al.sub.5O.sub.12:Ce,
Tb.sub.3Ga.sub.5O.sub.12:Ce, and Lu.sub.3Ga.sub.5O.sub.12:Ce. In
one example, the adjustment of color point of the illumination
device may be accomplished by replacing sidewall insert 107 and/or
the output window 108, which similarly may be coated or impregnated
with one or more wavelength converting materials. In one embodiment
a red emitting phosphor such as a europium activated alkaline earth
silicon nitride (e.g., (Sr,Ca)AlSiN.sub.3:Eu) covers a portion of
sidewall insert 107 and bottom reflector insert 106 at the bottom
of the cavity 109, and a YAG phosphor covers a portion of the
output window 108. In another embodiment, a red emitting phosphor
such as alkaline earth oxy silicon nitride covers a portion of
sidewall insert 107 and bottom reflector insert 106 at the bottom
of the cavity 109, and a blend of a red emitting alkaline earth oxy
silicon nitride and a yellow emitting YAG phosphor covers a portion
of the output window 108. In some embodiments, the phosphors are
mixed in a suitable solvent medium with a binder and, optionally, a
surfactant and a plasticizer. The resulting mixture is deposited by
any of spraying, screen printing, blade coating, or other suitable
means. By choosing the shape and height of the sidewalls that
define the cavity, and selecting which of the parts in the cavity
will be covered with phosphor or not, and by optimization of the
layer thickness and concentration of the phosphor layer on the
surfaces of light mixing cavity 109, the color point of the light
emitted from the module can be tuned as desired.
[0038] In one example, a single type of wavelength converting
material may be patterned on the sidewall, which may be, e.g., the
sidewall insert 107 shown in FIG. 5B. By way of example, a red
phosphor may be patterned on different areas of the sidewall insert
107 and a yellow phosphor may cover the output window 108. The
coverage and/or concentrations of the phosphors may be varied to
produce different color temperatures. It should be understood that
the coverage area of the red and/or the concentrations of the red
and yellow phosphors will need to vary for different illumination
modules 100 in order for the different illumination modules 100 to
produce the same desired color temperatures if the blue light
produced by the LEDs 102 in the different illumination modules 100
varies. The color performance of the LEDs 102, red phosphor on the
sidewall insert 107 and the yellow phosphor on the output window
108 may be measured before assembly and selected based on
performance so that the assembled pieces produce the desired color
temperature.
[0039] In many applications it is desirable to generate white light
output with a correlated color temperature (CCT) less than 4,200
degrees Kelvin, such as less than 3,100 degrees Kelvin. For
example, in many applications, white light with a CCT of 2,700
degrees Kelvin is desired. Some amount of red emission is generally
required to convert light generated from LEDs emitting in the blue
or UV portions of the spectrum to a white light output with a CCT
less than 4,200 degrees Kelvin. Efforts are being made to blend
yellow phosphor with red emitting phosphors such as CaS:Eu, SrS:Eu,
SrGa.sub.2S.sub.4:Eu, Ba.sub.3Si.sub.6O.sub.12N.sub.2:Eu,
(Sr,Ca)AlSiN.sub.3:Eu, CaAlSiN.sub.3:Eu, CaAlSi(ON).sub.3:Eu,
Ba.sub.2SiO.sub.4:Eu, Sr.sub.2SiO.sub.4:Eu, Ca.sub.2SiO.sub.4:Eu,
CaSi.sub.2O.sub.2N.sub.2:Eu, SrSi.sub.2O.sub.2N.sub.2:Eu,
BaSi.sub.2O.sub.2N.sub.2:Eu,
Sr.sub.8Mg(SiO.sub.4).sub.4Cl.sub.2:Eu,
Li.sub.2NbF.sub.7:Mn.sup.4+, Li.sub.3ScF.sub.6:Mn.sup.4+,
La.sub.2O.sub.2S:Eu.sup.3+ and MgO.MgF.sub.2.GeO.sub.2:Mn.sup.4+ to
reach the required CCT. However, color consistency of the output
light is typically poor due to the sensitivity of the CCT of the
output light to the red phosphor component in the blend. Poor color
distribution is more noticeable in the case of blended phosphors,
particularly in lighting applications. By coating output window 108
with a phosphor or phosphor blend that does not include any red
emitting phosphor, problems with color consistency may be avoided.
To generate white light output with a CCT less than 4,200 degrees
Kelvin, a red emitting phosphor or phosphor blend is deposited on
any of the sidewalls and bottom reflector of LED based illumination
module 100. The specific red emitting phosphor or phosphor blend
(e.g., peak wavelength emission from 600 nanometers to 700
nanometers) as well as the concentration of the red emitting
phosphor or phosphor blend are selected to generate a white light
output with a CCT less than 4,200 degrees Kelvin. In this manner,
an LED based illumination module may generate white light with a
CCT less than 4,200K with an output window that does not include a
red emitting phosphor component.
[0040] In some embodiments, any of the bottom reflector 106, cavity
body 105, output window 108, and sidewall insert 107 may be
constructed from or include a PTFE material at an interior surface
facing light mixing cavity 109. In one example, any of the output
window 108, bottom reflector insert 106, sidewall insert 107, and
cavity body 105 may be made from a PTFE material. In another
example, any of the output window 108, bottom reflector insert 106,
sidewall insert 107, and cavity body 105 may include a PTFE layer
backed by a reflective layer such as a polished metallic layer. The
PTFE material may be formed from sintered PTFE particles. In some
embodiments, portions of any of the interior facing surfaces of any
of the bottom reflector 106, cavity body 105, and sidewall insert
107 constructed from a PTFE material may be coated with a
wavelength converting material. In other embodiments, a wavelength
converting material may be mixed with the PTFE material. For
purposes of this patent document, a wavelength converting material
is any single chemical compound or mixture of different chemical
compounds that performs a color conversion function, e.g., absorbs
an amount of light of one peak wavelength, and in response, emits
an amount of light at another peak wavelength.
[0041] In other embodiments, any of the bottom reflector 106,
cavity body 105, and sidewall insert 107 may be constructed from or
include a reflective, ceramic material, such as ceramic material
produced by CerFlex International (The Netherlands), at an interior
surface facing light mixing cavity 109. In one example, portions of
any of the interior facing surfaces of any of the bottom reflector
106, cavity body 105, and sidewall insert 107 constructed from a
ceramic material may be coated with a wavelength converting
material.
[0042] In other embodiments, any of the bottom reflector 106,
cavity body 105, and sidewall insert 107 may be constructed from or
include a reflective, metallic material, such as aluminum or
Miro.RTM. produced by Alanod (Germany), at an interior surface
facing light mixing cavity 109. In one example, portions of any of
the interior facing surfaces of any of the bottom reflector 106,
cavity body 105, and sidewall insert 107 constructed from a
reflective metallic material may be coated with a wavelength
converting material.
[0043] In other embodiments, any of the bottom reflector 106,
cavity body 105, and sidewall insert 107 may be constructed from or
include a reflective, plastic material, such as MCPET at an
interior surface facing light mixing cavity 109. In one example,
portions of any of the interior facing surfaces of any of the
bottom reflector 106, cavity body 105, and sidewall insert 107
constructed from a reflective plastic material may be coated with a
wavelength converting material.
[0044] Cavity 109 may be filled with a non-solid material, such as
air or an inert gas, so that the LEDs 102 emits light into the
non-solid material. By way of example, the cavity may be
hermetically sealed and Argon gas used to fill the cavity.
Alternatively, Nitrogen may be used. In other embodiments, cavity
109 may be filled with a solid encapsulate material. By way of
example, silicone may be used to fill the cavity.
[0045] The PTFE material is less reflective than other materials
that may be used for the bottom reflector insert 106, sidewall
insert 107 or cavity body 105, such as Miro.RTM. produced by
Alanod. In one example, the blue light output of an LED based
illumination module 100 constructed with uncoated Miro.RTM.
sidewall insert 107 was compared to the same module constructed
with an uncoated PTFE sidewall insert 107 constructed from sintered
PTFE material manufactured by Berghof (Germany). Blue light output
from module 100 was decreased 7% by use of a PTFE sidewall insert.
Similarly, blue light output from module 100 was decreased 5%
compared to uncoated Miro.RTM. sidewall insert 107 by use of an
uncoated PTFE sidewall insert 107 constructed from sintered PTFE
material manufactured by W.L. Gore (USA). Light extraction from the
module 100 is directly related to the reflectivity inside the
cavity 109, and thus, the inferior reflectivity of the PTFE
material, compared to other available reflective materials, would
lead away from using the PTFE material in the cavity 109.
Nevertheless, the inventors have determined that when the PTFE
material is coated with phosphor, the PTFE material unexpectedly
produces an increase in luminous output compared to other more
reflective materials, such as Miro.RTM., with a similar phosphor
coating. In another example, the white light output of an
illumination module 100 targeting a correlated color temperature
(CCT) of 4,000 degrees Kelvin constructed with phosphor coated
Miro.RTM. sidewall insert 107 was compared to the same module
constructed with a phosphor coated PTFE sidewall insert 107
constructed from sintered PTFE material manufactured by Berghof
(Germany). White light output from module 100 was increased 7% by
use of a phosphor coated PTFE sidewall insert compared to phosphor
coated Miro.RTM.. Similarly, white light output from module 100 was
increased 14% compared to phosphor coated Miro.RTM. sidewall insert
107 by use of a PTFE sidewall insert 107 constructed from sintered
PTFE material manufactured by W.L. Gore (USA). In another example,
the white light output of an illumination module 100 targeting a
correlated color temperature (CCT) of 3,000 degrees Kelvin
constructed with phosphor coated Miro.RTM. sidewall insert 107 was
compared to the same module constructed with a phosphor coated PTFE
sidewall insert 107 constructed from sintered PTFE material
manufactured by Berghof (Germany). White light output from module
100 was increased 10% by use of a phosphor coated PTFE sidewall
insert compared to phosphor coated Miro.RTM.. Similarly, white
light output from module 100 was increased 12% compared to phosphor
coated Miro.RTM. sidewall insert 107 by use of a PTFE sidewall
insert 107 constructed from sintered PTFE material manufactured by
W.L. Gore (USA).
[0046] Thus, it has been discovered that, despite being less
reflective, it is desirable to construct phosphor covered portions
of the light mixing cavity 109 from a PTFE material. Moreover, the
inventors have also discovered that phosphor coated PTFE material
has greater durability when exposed to the heat from LEDs, e.g., in
a light mixing cavity 109, compared to other more reflective
materials, such as Miro.RTM., with a similar phosphor coating.
[0047] Although it may seem desirable to apply thick layers of
phosphors (e.g., layer thickness greater than five times the
average diameter of the phosphor particles) onto a substrate to
form either a reflective or transmissive color converting element,
the inventors have discovered that photons tend to become trapped
in thick layers and efficiency is lost. In contrast, by utilizing
thin layers packed to the appropriate density, a high percentage of
incoming photons are either color converted or recovered in an
unconverted state as useable light.
[0048] In one aspect phosphor may be applied in a thin layer to
provide highly efficient color conversion in a reflective mode and
in a transmissive mode. In a reflective mode, the thin layer is
densely packed to maximize the amount of incident light that is
color converted. In a transmissive mode, the thin layer is sparsely
packed to allow a portion of the incident light to pass through
unconverted. In one example, phosphor is deposited on a substrate
to a thickness of less than five times the average diameter of the
phosphor particles. In another example, phosphor is deposited on a
substrate to a thickness of less than three times the average
diameter of the phosphor particles. In yet another example,
phosphor is deposited on a substrate in a single layer. In examples
that provide color conversion in a transmissive mode, phosphor is
deposited with a packing density less than 90%, such that a portion
of light incident to the substrate is either reflected or
transmitted without color conversion. In examples that provide
color conversion in a reflective mode, phosphor is deposited with a
packing density greater than 50%, such that substantially all light
incident to the substrate is color converted. In another aspect,
the aforementioned thin layers of phosphor are deposited on a PTFE
substrate. It has been discovered that phosphor particles deposited
onto a PTFE substrate in a thin layer generate highly efficient
color conversion in an LED based illumination device.
[0049] FIG. 6 is a flow chart illustrative of a method 150 of
applying a thin layer of phosphor onto a reflective substrate. In
the illustrated example of method 150, a low temperature process is
employed to deposit a thin layer of phosphor particles on a PTFE
substrate. In other examples, method 150 may be employed to deposit
a thin layer of phosphor particles on other reflective surfaces
(e.g., glass, aluminum, coated aluminum, ceramic, or plastic
substrates). In the low temperature process a binder remains on the
substrate with the phosphor particles as part of the final product,
rather than being decomposed (typically by a high temperature
curing step).
[0050] In block 151, a polymer binder (e.g., ethyl cellulose,) is
mixed with a solvent (e.g., butoxyethyl acetate) and combined with
a wavelength converting material (e.g., phosphor particles or blend
of phosphor particles) to form a homogeneous phosphor suspension.
In some examples, the average particle size of the phosphor
particles may be between one and twenty five microns. Different
polymer binders may be employed as part of method 150 (e.g.,
polyvinyl butyral, cellulose based binders, silicone based binders,
and urethane based binders). Similarly, solvents selected for their
compatibility with the selected binders (e.g., terpineol, isobutyl
alcohol, butyl carbolite acetate, butyl cellulose, silicone
solvents, and urethane solvents) may be employed as part of method
150. In some embodiments, in addition to the phosphor particles, a
small amount (e.g., 0.1% to 5% by weight) of plasticizer (e.g.,
diisobutyl phthalate) may be added to facilitate adhesion of the
phosphor particles to the substrate. In some embodiments, a
surfactant (e.g., stearic acid, Polyethylene glycol (PEG)) may be
added to the phosphor particles. For example, a small amount of
surfactant (e.g., less than 5% by weight) may be added. The
surfactant acts to keep the phosphor particles from clumping
together and promotes the even distribution of phosphor particles
in the suspension.
[0051] In different examples, the proportion of phosphor particles
to reduced polymer binder may vary. In one example, phosphor
particles may be mixed with the reduced polymer binder with solvent
in a 50:50 proportion by weight. This proportion has been found
useful to generate color converting layers with a packing density
greater than 90% with a thickness less than five times the average
diameter of the phosphor particles. In another example, the
phosphor particles may be mixed with the reduced polymer binder in
a proportion of 20:80. This proportion has been found useful to
generate color converting layers with a packing density less than
95% with a thickness less than three times the average diameter of
the phosphor particles.
[0052] In block 152, the homogeneous phosphor suspension is applied
to a PTFE substrate to form an uncured color converting layer. The
homogeneous phosphor suspension may be applied to the PTFE
substrate by a number of methods. Examples of suitable methods
include blade coating, screen printing, and spraying. The solvent
may be mixed with the polymer binder in differing proportions
depending on the desired viscosity. For example, for effective
application to a substrate by blade coating or screen printing,
solvent may be mixed with the polymer binder in a suitable
proportion (e.g., between 5:1 and 10:1 by weight). For effective
application to a substrate by spraying, solvent may be mixed with
the polymer binder in a suitable proportion (e.g., between 10:1 and
20:1 by weight).
[0053] In some examples the homogeneous suspension may be applied
to a surface by blade coating. The suspension is dispersed using a
sapphire or stainless steel blade. An automatic film applicator
maintains a constant distance between the blade and the surface. A
stainless steel stencil may be employed to direct the application
of the suspension to a specific portion of the surface (e.g.,
specific pattern or surface geometry).
[0054] In some examples, the homogeneous suspension may also be
applied to a surface by screen printing. Screens may be customized
to completely mask or partially mask various sizes and shapes. Open
portions of the screen may include different aspect ratios to vary
the concentration of the applied phosphor particles. For screen
printing, custom made screens with mesh numbers from 150 to 300
have been found to be effective. Pre cut substrates (e.g., PTFE,
Alanod, MCPET) are attached to an aluminum base under vacuum with a
screen overlay. A homogeneous suspension of phosphor particles is
dispersed using a suitable squeeze applicator (e.g., rubber
applicator) at constant speed and pressure.
[0055] In block 153, the uncured color converting layer is heated
to a temperature above the flash point of the solvent to vaporize
the solvent to form a cured color converting layer with a thickness
of less than five times the average diameter of the phosphor
particles. For example, the uncured color converting layer is
heated to a temperature of 80 to 150 degrees Centigrade for 30 to
300 minutes to vaporize the solvent. The process temperature
remains below the temperature where the binder begins to decompose.
Thus, the cured color converting layer includes a thin layer of
phosphor particles suspended in the polymer binder. The polymer
binder keeps the phosphor particles positioned with respect to one
another in a stable manner. Furthermore, the low temperature
process does not denature, or otherwise decompose or alter the
chemical composition of the phosphors, thus their color conversion
properties remain intact. This is particularly important for
certain families of phosphors (e.g., nitridosilicates and oxy
silicon nitrides). In addition, the low temperature process does
not decompose, denature, or otherwise degrade the mechanical
structure of the PTFE material, thereby maintaining its diffuse,
reflective properties.
[0056] Phosphor particles of varying diameter may be effectively
employed using method 150. The inventors have found the use of
phosphor particles with an average diameter of 6-8 .mu.m to be
useful. However, phosphor particles with an average diameter
between 1 .mu.m and 25 .mu.m may also be used beneficially.
[0057] FIG. 7 is a flow chart illustrative of a method 160 of
applying a thin, semi-transparent color converting layer onto a
transparent substrate (e.g., sapphire, alumina, glass,
polycarbonate, plastic). In block 161, a polymer binder (e.g.,
ethylcellulose) is mixed with a solvent (e.g., butoxyethyl acetate)
and combined with phosphor particles to form a homogeneous phosphor
suspension. Different polymer binders may be employed as part of
method 160 (e.g., polyvinyl butyral, cellulose based binders,
silicone based binders, and urethane based binders). Similarly,
solvents selected for their compatibility with the selected binders
(e.g., terpineol, isobutyl alcohol, butyl carbolite acetate, butyl
cellulose, silicone solvents, and urethane solvents) may be
employed as part of method 160. In some embodiments, in addition to
the phosphor particles, a plasticizer (e.g., diisobutyl phthalate)
may be added to facilitate adhesion of the phosphor particles to
the substrate. In some embodiments, a surfactant (e.g., stearic
acid, PEG) may be added. The surfactant acts to keep the phosphor
particles from clumping together and promotes the even distribution
of phosphor particles in the suspension.
[0058] In different examples, the proportion of phosphor particles
to reduced polymer binder may vary. In one example, phosphor
particles may be mixed with the reduced polymer binder in a 95:5
proportion by weight. This proportion has been found useful to
produce a semi-transparent color converting layer with a packing
density less than 95% with a thickness less than three times the
average diameter of the phosphor particles where at least 10% of
incident light is transmitted through the layer without color
conversion. In some examples less than 30% of incident light is
transmitted through the layer without color conversion.
[0059] In block 162, the homogeneous phosphor suspension is applied
to a transparent substrate to form an uncured, semi-transparent
color converting layer as discussed with respect to method 150. The
homogeneous phosphor suspension may be applied to the transparent
substrate by a number of methods. Examples of suitable methods
include blade coating, screen printing, and spraying. The solvent
may be mixed with the polymer binder in differing proportions
depending on the desired viscosity. For example, for effective
application to a substrate by blade coating or screen printing,
solvent may be mixed with the polymer binder in a suitable
proportion (e.g., between 5:1 and 10:1 by weight). For effective
application to a substrate by spraying, solvent may be mixed with
the polymer binder in a suitable proportion (e.g., between 10:1 and
20:1 by weight).
[0060] In block 163, the uncured, semi-transparent color converting
layer is heated to a temperature above the flash point of the
solvent to vaporize the solvent to form a cured, semi-transparent
color converting layer with a thickness of less than five times the
average diameter of the phosphor particles.
[0061] In some examples, the process temperature remains below the
temperature where the binder begins to decompose. In one example,
the uncured, semi-transparent color converting layer is heated to a
temperature of 100 to 120 degrees Centigrade for 30 to 60 minutes
to vaporize the butoxyethyl acetate solvent. Thus, the cured,
semi-transparent color converting layer includes a thin layer of
phosphor particles suspended in the polymer binder. The polymer
binder keeps the phosphor particles positioned with respect to one
another in a stable manner. Furthermore, the low temperature
process does not denature, or otherwise decompose or alter the
chemical composition of the phosphors, thus their color conversion
properties remain intact. This is particularly important for
certain families of phosphors (e.g., nitridosilicates and oxy
silicon nitrides).
[0062] In some examples, a process temperature is employed that
causes the binder to decompose or otherwise denature. By removing
the binder, its effect on the efficiency of light transmission
through the cured, semi-transparent color converting layer is
negated. A plasticizer that withstands the curing temperatures may
be employed to adhere the phosphor particles to the substrate or
maintain an even distribution of phosphor particles within the
cured, semi-transparent color converting layer. In one example, a
temperature of 360 degrees Centigrade may be employed to decompose
an ethylcellulose binder and the butoxyethyl acetate solvent
completely.
[0063] Phosphor particles of varying diameter may be effectively
employed using method 160. The inventors have found the use of
phosphor particles with an average diameter of 6-8 .mu.m to be
useful. However, phosphor particles with an average diameter
between 1 .mu.m and 25 .mu.m may also be used beneficially.
[0064] FIG. 8 is illustrative of a cross-sectional view of LED
based illumination module 100 that includes reflective color
converting elements 129 and 130 coated in accordance with method
150 and a transmissive color converting element 133 coated in
accordance with method 160. In one aspect LED based illumination
module 100 includes a transmissive color converting element 133
that includes an optically transparent layer 134 and
semi-transparent color converting layer 135 fixed to the optically
transparent layer 134. In another aspect, LED based illumination
module 100 includes a reflective color converting element 130 that
includes a reflective layer 131 and color converting layer 132
fixed to reflective layer 131. In yet another aspect, LED based
illumination module 100 includes a reflective color converting
element 129 that includes a reflective layer 128 and color
converting layer 127 fixed to reflective layer 128. In one
embodiment, transmissive color converting element 133 is output
window 108 and reflective color converting element 130 is sidewall
insert 107. In addition, in one embodiment, reflective color
converting element 129 is bottom reflector insert 106. LEDs 102
emit blue photons that interact with color converting elements 129,
130, and 133.
[0065] Transmissive color converting element 133 provides highly
efficient color conversion in a transmissive mode. Color converting
layer 135 includes a sparse, thin layer of phosphor applied in
accordance with method 160. Transmission of unconverted light is
not desirable in lighting devices pumped with UV or sub-UV
radiation because of the health risk to humans exposed to radiation
at these wavelengths. However, for an LED based illumination module
pumped by LEDs with emission wavelengths above UV, it is desirable
for a significant percentage of unconverted light (e.g., blue light
emitted from LEDs 102) to pass through light mixing cavity 109 and
through output window 108 (e.g., transmissive color converting
element 133) without color conversion. This promotes high
efficiency because losses inherent to the color conversion process
are avoided. Sparsely packed, thin layers of phosphor are suitable
to color convert a portion of incident light. For example, it is
desirable to allow at least ten percent of incident light to be
transmitted through the color converting layer 135 without
conversion. In particular, a color converting layer that is less
than three times an average diameter of the phosphor particles with
a packing density of phosphor particles in the polymer matrix of
greater than 80% has been found to perform advantageously.
[0066] In one embodiment, color converting layer 132 is deposited
on reflective layer 131 with a thickness that is two times the
average diameter of the phosphor particles with a packing density
greater than 90%. In this embodiment, the average phosphor particle
diameter is between six and eight microns. To deposit color
converting layer 132 on reflective layer 131, 50 to 100 grams of
either one of or a combination of ethyl cellulose and polyvinyl
butyral binder is mixed with 200 to 600 grams of suitable solvent
such as terpineol, isobutyl alcohol, butyl carbolite acetate, or
butyl cellulose. The mixture is rolled in a jar by a slow moving
roller for 2 to 4 days until a clear binder paste is formed. The
viscosity of the binder paste varies with the solvent content. In a
separate mixture, 10 to 30 grams of a surfactant such as stearic
acid or polyethylene glycol is mixed in 50 to 100 grams of solvent
to form a surfactant paste. In a final mixture, 1 to 5 grams of red
emitting phosphor particles is mixed with 1 to 10 grams of the
binder paste, 0.1 to 0.5 grams of the surfactant paste and 2 to 10
drops of plasticizer in a 3D Mixer (THINKY ARE-250) for 2 to 10
minutes to generate a homogeneous suspension of phosphor particles.
Depending on the application, the ratio of binder, surfactant,
plasticizer and phosphor is tuned.
[0067] In a more specific example, 10 grams of ethyl cellulose
binder is mixed with 80 grams of butyl carbolite acetate (BAC)
solvent in a glass jar. The mixture is stirred for a few hours in a
glass jar and then rolled in a slow moving roller for 2 to 4 days
until a clear binder paste is formed. In a separate mixture, 10
grams of polyethylene glycol surfactant is mixed in 100 grams of
BAC until an optically clear surfactant paste is formed. One gram
of red emitting phosphor {(Sr,Ca)AlSiN.sub.3:Eu} of 10 micron
average particle size is mixed with 1 gram of binder paste, 0.1
grams of surfactant paste and 2 drops of plasticizer in a 3D Mixer
(THINKY ARE-250) for 2 minutes.
[0068] Color converting layer 132 may be deposited onto reflective
layer 131 by blade coating. An automatic film applicator (Elcometer
4340) is used with pre-cut stainless steel stencils to determine
the coverage area. While holding the reflective layer 131 with a
stencil under vacuum on an aluminum base, the homogeneous
suspension of phosphor particles is dispersed using a slow moving
(e.g., 5 to 60 mm/sec) sapphire or stainless steel blade. After
coating, reflective color converting element 130 is transferred
into an oven and heated at 80 to 150 degrees Centigrade for 1 to 5
hours in open atmosphere to form the cured color converting layer
132.
[0069] Color converting layer 132 may be deposited onto reflective
layer 131 by screen printing. Screens with mesh numbers from 150 to
300 are used. The screens are either open completely or masked with
various sizes and shapes of different aspect ratios. Using the
aforementioned automatic film applicator, reflective layer 131 with
required screen are attached to an aluminum base under vacuum and
the homogeneous suspension of phosphor particles is dispersed using
a suitable squeeze under constant pressure and speed (e.g., 5 to
100 mm/sec). After screen printing, reflective color converting
element 130 is transferred into an oven and heated at 80 to 150
degrees Centigrade for 1 to 5 hours in open atmosphere to form the
cured color converting layer 132.
[0070] After heat treatment, the cured color converting layer 132
is employed in an LED based illumination module to generate white
light with a CCT between 2,000 degrees Kelvin to 6,000 degrees
Kelvin.
[0071] FIG. 9 illustrates a cross-sectional view of a portion of
the LED illumination module 100 focusing on the interaction of
photons emitted by LED 102 with transmissive color converting
element 133. Transmissive color converting element 133 includes
transmissive layer 134 and semi-transparent color converting layer
135. Transmissive layer 134 may be constructed from an optically
clear medium (e.g., glass, sapphire, polycarbonate, plastic).
Transmissive color converting element 133 may include additional
layers (not shown) to enhance optical system performance. In one
example, transmissive color converting element 133 may include
optical films such as a dichromic filter, a low index coating,
additional layers such as a layer of scattering particles, or
additional color converting layers including phosphor particles.
Semi-transparent, color converting layer 135 includes phosphor
particles 141 embedded in a polymer binder 142.
[0072] In one embodiment, semi-transparent color converting layer
135 is deposited on optically transparent layer 134 with a
thickness T.sub.135 that is three times the average diameter of the
phosphor particles 141 with a packing density greater than 80%. The
average diameter of phosphor particles 141 may be between one
micrometer and twenty five micrometers. In some embodiments,
phosphor particles 141 average five to ten micrometers in diameter.
Phosphor particles 141 are arranged to enable a portion of light to
be transmitted through transmissive color converting element 133
without color conversion. In this embodiment, the average phosphor
particle diameter D.sub.AVG is ten microns. To deposit
semi-transparent color converting layer 135 on optically
transparent layer 134, 10 grams of ethyl cellulose binder is mixed
80 grams of butyl carbolite acetate (BAC) solvent in a glass jar
and stirred for few hours in a glass jar of wide mouth and then
rolled in slow moving roller for 2 to 4 days until a clear binder
paste is formed. In a separate mixture, 10 grams of polyethylene
glycol surfactant is mixed in 100 grams of BAC until an optically
clear surfactant paste is formed. In a final mixture, one gram of
yellow emitting phosphor such as YAG:Ce of 10 micron average
particle size is mixed with 1.2 grams of binder paste, 0.1 grams of
surfactant paste, and 2 drops of plasticizer in a 3D Mixer (THINKY
ARE-250) for 2 minutes.
[0073] Semi-transparent color converting layer 135 may be deposited
onto optically transparent layer 134 by blade coating. An automatic
film applicator (Elcometer 4340) is used with pre-cut stainless
steel stencils to determine the coverage area. While holding the
optically transparent layer 134 with a stencil under vacuum on an
aluminum base, the homogeneous suspension of phosphor particles is
dispersed using a slow moving (e.g., 10 mm/sec) sapphire or
stainless steel blade.
[0074] Semi-transparent color converting layer 135 may be deposited
onto optically transparent layer 134 by screen printing. Screens
with mesh numbers from 150 to 300 are used. The screens are either
open completely or masked with various sizes and shapes of
different aspect ratios. Using the aforementioned automatic film
applicator, optically transparent layer 134 with required screen
are attached to an aluminum base under vacuum and the homogeneous
suspension of phosphor particles is dispersed using a suitable
squeeze under constant pressure and speed (e.g., 20 mm/sec).
[0075] Semi-transparent color converting layer 135 may be deposited
onto optically transparent layer 134 by spray painting. A low
viscosity slurry is prepared by mixing 1 gram of yellow emitting
phosphor such as YAG:Ce 1.2 gram of the binder paste, 0.1 gram of
the surfactant paste, 2 drops of plasticizer and ten grams of BAC.
A manual spray gun of 50 cc capacity at 10 P.S.I with fine tip has
been used with satisfactory results.
[0076] After coating, transmissive color converting element 133 is
transferred into an oven and heated to 120 degrees Centigrade for 1
hour in open atmosphere to form the cured semi-transparent color
converting layer 135.
[0077] After heat treatment, the cured semi-transparent color
converting layer 135 is employed in an LED based illumination
module to generate white light with a CCT between 2,000 degrees
Kelvin to 6,000 degrees Kelvin.
[0078] As depicted in FIG. 9, blue photon 139 emitted from LED 102
passes through transmissive color converting element 133 without
color conversion and contributes to combined light 140 as a blue
photon. However, blue photon 138 emitted from LED 102 is absorbed
by a phosphor particle embedded in color converting layer 135. In
response to the stimulus provided by blue photon 138, the phosphor
particle emits a light of a longer wavelength in an isotropic
emission pattern. In the illustrated example, the phosphor particle
emits yellow light. As illustrated in FIG. 9, a portion of the
yellow emission passes through transmissive color converting
element 133 and contributes to combined light 140 as a yellow
photon. Another portion of the yellow emission is absorbed by
adjacent phosphor particles and is either reemitted or lost. Yet
another portion of the yellow emission is scattered back into light
mixing cavity 109 where it is either reflected back toward
transmissive color converting element 133 or is absorbed and lost
within light mixing cavity 109.
[0079] FIG. 10 illustrates a cross-sectional view of a portion of
LED illumination module 100 with the transmissive color converting
element 133 having a color converting layer 135 with a single layer
of phosphor particles 141. In one embodiment, phosphor particles
141 may be spaced apart by polymer binder 142. In another
embodiment, phosphor particles 141 may be deposited on transmissive
layer 134 and the polymer binder 142 removed as described in this
patent document. In either embodiment, the layer thickness
T.sub.135 is so small that reabsorbtion of converted light by
neighboring phosphor particles is minimized. In addition, Fresnel
losses associated with light transmission through color converting
layer 135 are minimized. Furthermore, losses due to total internal
reflection (TIR) within color converting layer 135 are minimized.
As such, phosphor particles fixed to transmissive layer 134 in a
monolayer have been found to transmit unconverted light and
converted light in an efficient manner.
[0080] For an LED based illumination module, it is desirable to
convert a portion of light emitted from the LEDs (e.g., blue light
emitted from LEDs 102) to longer wavelength light in light mixing
cavity 109 while minimizing photon loses. Densely packed, thin
layers of phosphor are suitable to efficiently color convert a
significant portion of incident light while minimizing loses
associated with reabsorption by adjacent phosphor particles, total
internal reflection (TIR), and Fresnel effects.
[0081] FIG. 11 illustrates a cross-sectional view of a portion of
the LED illumination module 100 with the reflective color
converting element 130 having a color converting layer 132 with a
thickness less than five times the average diameter of phosphor
particles 141. The average diameter of phosphor particles 141 may
be between one micrometer and twenty five micrometers. In some
embodiments, the average diameter of phosphor particles 141 is
between five and ten micrometers. Phosphor particles 141 are
arranged with a packing density of more than 80% to increase the
probability that an incoming photon of light will interact with a
phosphor particle to generate converted light. For example, blue
photon 137 emitted from LED 102 is incident to reflective color
converting element 130 and is absorbed by a phosphor particle of
color converting layer 132. In response to the stimulus provided by
blue photon 137, the phosphor particle emits a light of a longer
wavelength in an isotropic emission pattern. In the illustrated
example, the phosphor particle emits red light. As illustrated in
FIG. 11, a portion of the red emission enters light mixing cavity
109. Another portion of the red emission is absorbed by adjacent
phosphor particles and is either reemitted or lost. Yet another
portion of the red emission is reflected off of reflective layer
131 and is either transmitted through color converting layer 132 to
light mixing cavity 109 or is absorbed by an adjacent phosphor
particle and is either reemitted or lost.
[0082] FIG. 12 illustrates a cross-sectional view of a portion of
the LED illumination module 100 with the reflective color
converting element 130 having a color converting layer 132 with a
single layer of phosphor particles 141. In one embodiment, phosphor
particles 141 may be spaced apart by polymer binder 142, for
example, as described in method 150. In another embodiment,
phosphor particles 141 may be deposited on reflective layer 131 and
the polymer binder 142 removed as discussed in this patent
document. In either embodiment, the layer thickness is so small
that reabsorbtion of converted light by neighboring phosphor
particles is minimized. In addition, Fresnel losses associated with
light transmission through color converting layer 132 are
minimized. Furthermore, losses due to total internal reflection
(TIR) within color converting layer 132 are minimized. As such,
phosphor particles fixed to reflective layer 131 in a monolayer
have been found to efficiently convert light.
[0083] FIG. 13 illustrates a cross-sectional view of LED
illumination module 100 with a transmissive color converting
assembly 144. In the depicted embodiment, transmissive color
converting assembly 144 includes a color converting layer 135 with
a single layer of phosphor particles 141. Phosphor particles 141
may be deposited on transmissive layer 134 and the polymer binder
142 removed as described in this patent document. The color
converting layer 135 is enclosed by a second transmissive layer 136
that is sealed to transmissive layer 134 by seal element 143. In
this manner color converting layer 135 is isolated from the
environment. In some embodiments, seal element 143 may be a frit
seal glass such as Pb free Bi based glass powder (BSF-1307). In
some other embodiments, seal element 143 may be an optical adhesive
(e.g., adhesive Type J-91 Lens Bond/optical cement).
[0084] FIG. 14 is illustrative of a top view of transmissive color
converting assembly 144. In particular, seal element 143 is
illustrated. Seal element 143 extends along the perimeter of
assembly 144. In this manner, light emitted from LED based
illumination device 100 is minimally impacted by the presence of
sealing element 143. By isolating color converting layer 135 from
the environment, phosphors may be successfully employed that are
typically sensitive to environmental factors such as humidity.
Also, by minimizing the presence of binders in color converting
layer 135, transmissive color converting assembly 144 may be
operated at higher temperatures without suffering degradation of
optical performance.
[0085] FIG. 15 is a flow chart illustrative of a method 170 of
enclosing a thin, semi-transparent color converting layer between
two transparent substrates (e.g., sapphire, alumina, glass,
polycarbonate, plastic) and sealing the color converting layer from
the environment. In one aspect, the color converting layer does not
include binders or solvents. In this manner, as the phosphors are
heated during operation, there is no impact on light performance
due to binder degradation. In another aspect, separating the color
converting layer from the environment permits a broad range of
environmentally sensitive phosphors to be used as an element of LED
based illumination module 100.
[0086] In block 171, a polymer binder (e.g., ethylcellulose) is
mixed with a solvent (e.g., butoxyethyl acetate) and combined with
phosphor particles to form a homogeneous phosphor suspension.
Different polymer binders may be employed as part of method 160
(e.g., polyvinyl butyral, cellulose based binders, silicone based
binders, and urethane based binders). Similarly, solvents selected
for their compatibility with the selected binders (e.g., terpineol,
isobutyl alcohol, butyl carbolite acetate, butyl cellulose,
silicone solvents, and urethane solvents) may be employed as part
of method 170. In some embodiments, in addition to the phosphor
particles, a plasticizer (e.g., diisobutyl phthalate) may be added
to facilitate adhesion of the phosphor particles to the substrate.
In some embodiments, a surfactant (e.g., stearic acid, PEG) may be
added. The surfactant acts to keep the phosphor particles from
clumping together and promotes the even distribution of phosphor
particles in the suspension.
[0087] In different examples, the proportion of phosphor particles
to reduced polymer binder may vary. In one example, phosphor
particles may be mixed with the reduced polymer binder in a 95:5
proportion by weight. This proportion has been found useful to
generate color converting layers with a packing density less than
0.95 with a thickness less than three times the average diameter of
the phosphor particles to produce a semi-transparent color
converting layer where at least 10% of incident light is
transmitted through the layer without color conversion.
[0088] In block 172, the homogeneous phosphor suspension is applied
to a transparent substrate to form an uncured, semi-transparent
color converting layer as discussed with respect to method 155. The
homogeneous phosphor suspension may be applied to the transparent
substrate by a number of methods. Examples of suitable methods
include blade coating, screen printing, and spraying. The solvent
may be mixed with the polymer binder in differing proportions
depending on the desired viscosity. For example, for effective
application to a substrate by blade coating or screen printing,
solvent may be mixed with the polymer binder in a suitable
proportion (e.g., between 5:1 and 10:1 by weight). For effective
application to a substrate by spraying, solvent may be mixed with
the polymer binder in a suitable proportion (e.g., between 10:1 and
20:1 by weight).
[0089] In block 173, the uncured, semi-transparent color converting
layer is heated to a temperature sufficient to vaporize the solvent
and denature the binders to form a semi-transparent color
converting layer with a thickness of less than five times the
average diameter of the phosphor particles.
[0090] The process temperature is held above the temperature where
the binder begins to decompose. In one example, the uncured,
semi-transparent color converting layer is heated to a temperature
of 300 to 350 degrees Centigrade for 20 to 30 minutes. In this
manner, the semi-transparent color converting layer is
predominately comprised of phosphor particles with only trace
elements of binder material remaining.
[0091] In block 174, the color converting layer is enclosed between
the first transmissive element and a second transmissive element
(e.g., between two sheets of glass). A sealing element fixedly
couples the two transmissive elements and encloses the color
converting layer between the two transmissive elements. In this
manner, the color converting element is isolated from the
environment.
[0092] Phosphor particles of varying diameter may be effectively
employed using method 170. The inventors have found the use of
phosphor particles with an average diameter of 6-8 .mu.m to be
useful. However, phosphor particles with an average diameter
between 1 .mu.m and 25 .mu.m may also be used beneficially.
[0093] FIG. 16 illustrates a cross-sectional view of LED
illumination module 100 with a color converting layer 135 disposed
on transmissive layer 134 and encapsulated with a seal element 145.
In the depicted embodiment, transmissive color converting assembly
144 includes a color converting layer 135 with a single layer of
phosphor particles 141. Phosphor particles 141 may be deposited on
transmissive layer 134 and the polymer binder 142 removed as
described in this patent document. The color converting layer 135
is encapsulated by seal element 145. In this manner color
converting layer 135 is isolated from the environment. In some
embodiments, seal element 145 may be a metal silicate such as
sodium silicate or any organic metallic silicate such as
tetraethoxysilane. In some other embodiments, seal element 145 may
be an optical adhesive (e.g., adhesive Type J-91 Lens Bond/Optical
cement). By isolating color converting layer 135 from the
environment, phosphors may be successfully employed that are
typically sensitive to environmental factors such as humidity.
Also, by minimizing the presence of binders in color converting
layer 135, color converting layer 135 may be operated at higher
temperatures without suffering degradation of optical
performance.
[0094] FIG. 17 is a flow chart illustrative of a method 180 of
encapsulating a thin, semi-transparent color converting layer on a
transmissive substrate (e.g., sapphire, alumina, glass,
polycarbonate, plastic) and sealing the color converting layer from
the environment. In one aspect, the color converting layer does not
include binders or solvents. In this manner, as the phosphors are
heated during operation, there is no impact on light performance
due to binder degradation. In another aspect, separating the color
converting layer from the environment permits a broad range of
environmentally sensitive phosphors to be used as an element of LED
based illumination module 100.
[0095] In block 181, a polymer binder (e.g., ethylcellulose) is
mixed with a solvent (e.g., butoxyethyl acetate) and combined with
phosphor particles to form a homogeneous phosphor suspension as
discussed hereinbefore with respect to methods 155, 160, and
170.
[0096] In block 182, the homogeneous phosphor suspension is applied
to a transparent substrate to form an uncured, semi-transparent
color converting layer as discussed with respect to method 155.
[0097] In block 183, the uncured, semi-transparent color converting
layer is heated to a temperature sufficient to vaporize the solvent
and denature the binders to form a semi-transparent color
converting layer with a thickness of less than five times the
average diameter of the phosphor particles.
[0098] The process temperature is held above the temperature where
the binder begins to decompose. In one example, the uncured,
semi-transparent color converting layer is heated to a temperature
of 300 to 350 degrees Centigrade for 10 to 30 minutes. In this
manner, the semi-transparent color converting layer is
predominately comprised of phosphor particles with only trace
elements of binder material remaining.
[0099] In block 184, the color converting layer is encapsulated by
a sealing element. The sealing element isolates the color
converting layer 135 from the environment.
[0100] Phosphor particles of varying diameter may be effectively
employed using method 180. The inventors have found the use of
phosphor particles with an average diameter of 6-8 .mu.m to be
useful. However, phosphor particles with an average diameter
between 1 .mu.m and 25 .mu.m may also be used beneficially.
[0101] FIG. 18 illustrates a cross-sectional view of LED
illumination module 100 with a color converting layer 135 embedded
in the surface of transmissive layer 134. In the depicted
embodiment, a color converting layer 135 with a single layer of
phosphor particles 141 is embedded in the surface of a transmissive
layer 134. In one embodiment, transmissive layer 134 is low
softening glass such as float glass. Phosphor particles 141 may be
deposited on transmissive layer 134 and the polymer binder 142
removed as described in this patent document. Transmissive layer
134 is heated to its glass softening temperature and phosphor
particles 141 are embedded into the surface of the glass. In some
examples pressure is applied to facilitate embedding the phosphor
particles into the surface of the glass. Transmissive layer 134 is
cooled slowly to relieve internal stress. In this manner, phosphor
particles 141 are fixed to transmissive layer 134 without binders.
In this manner, color converting layer 135 may operate at higher
temperatures without impacting optical performance. In some
embodiments, the color converting layer 135 is subsequently
encapsulated by seal element 145. In this manner color converting
layer 135 is isolated from the environment.
[0102] FIG. 19 illustrates a reflective layer 131 of PTFE material.
As depicted, phosphor particles 141 are embedded in the PTFE
reflective layer 131. In some embodiments, phosphor particles 141
are mixed with PTFE granules, and subsequently sintered together to
achieve the desired optical structure that includes phosphor
particles 141. Reflective layer 131 may be subdivided into multiple
layers. For example, reflective layer 131 may include a reflective
layer embedded with phosphor particles 141 backed by another
reflective layer that does not include phosphor particles 141.
[0103] Although certain specific embodiments are described above
for instructional purposes, the teachings of this patent document
have general applicability and are not limited to the specific
embodiments described above. For example, any of sidewall insert
107, bottom reflector insert 106, and output window 108 may be
patterned with phosphor. Both the pattern itself and the phosphor
composition may vary. In one embodiment, the illumination device
may include different types of phosphors that are located at
different areas of the light mixing cavity 109. For example, a red
phosphor may be located on either or both of the insert 107 and the
bottom reflector insert 106 and yellow and green phosphors may be
located on the top or bottom surfaces of the window 108 or embedded
within the window 108. In one embodiment, a central reflector may
have patterns of different types of phosphor, e.g., a red phosphor
on a first area and a green phosphor on a separate second area. In
another embodiment, different types of phosphors, e.g., red and
green, may be located on different areas on the insert 107. For
example, one type of phosphor may be patterned on the sidewall
insert 107 at a first area, e.g., in stripes, spots, dots, or other
patterns, while another type of phosphor is located on a different
second area of the insert 107. If desired, additional phosphors may
be used and located in different areas in the cavity 109.
Additionally, if desired, only a single type of wavelength
converting material may be used and patterned in the cavity 109,
e.g., on the sidewalls. In another example, FIGS. 4A and 4B
illustrate the side walls as having a linear configuration, but it
should understood that the sidewalls may have any desired
configuration, e.g., curved, non-vertical, beveled etc. For
example, a higher transfer efficiency is achieved through the light
mixing cavity 109 by pre-collimation of the light using tapered
side walls. In another example, cavity body 105 is used to clamp
mounting board 104 directly to mounting base 101 without the use of
mounting board retaining ring 103. In other examples mounting base
101 and heat sink 130 may be a single component. In another
example, LED based illumination module 100 is depicted in FIGS. 1,
2, and 3 as a part of a luminaire 150. As illustrated in FIG. 3,
LED based illumination module 100 may be a part of a replacement
lamp or retrofit lamp. But, in another embodiment, LED based
illumination module 100 may be shaped as a replacement lamp or
retrofit lamp and be considered as such. Accordingly, various
modifications, adaptations, and combinations of various features of
the described embodiments can be practiced without departing from
the scope of the invention as set forth in the claims.
* * * * *