Light emitting device

• US 10,651,348 B2
• Filed: 05/30/2019
• Issued: 05/12/2020
• Est. Priority Date: 03/10/2016
• Status: Active Grant

• Current Assignee: Panasonic Intellectual Property Management Co., Ltd. (Panasonic Holdings Corporation)
• Original Assignee: Panasonic Intellectual Property Management Co., Ltd. (Panasonic Holdings Corporation)
• Inventors: Lee, Youshin, Oshio, Shozo, Okuno, Tatsuya, Abe, Takeshi, Nakamura, Masahiro
• Primary Examiner(s): Patel, Vip
• Application Number:
  US16/427,243
• Publication Number:
  US 20190280166A1
• Time in Patent Office: 348 Days
• Field of Search: None
• CPC Class Codes: C09K 11/08 containing inorganic luminescent materials
• CPC Class Codes: C09K 11/7774 Aluminates
• CPC Class Codes: F21S 2/00 Systems of lighting devices, not provided for in main groups F21S4/00 - F21S10/00 or F21S19/00, e.g. of modular construction
• CPC Class Codes: F21V 13/14 the elements being filters or photoluminescent elements, reflectors and refractors
• CPC Class Codes: F21V 9/32 characterised by the arrangement of the photoluminescent material
• CPC Class Codes: F21V 9/38 Combination of two or more photoluminescent elements of different materials
• CPC Class Codes: G02B 5/20 Filters polarising elements G02B5/30
• CPC Class Codes: H01L 33/16 with a particular crystal structure or orientation, e.g. polycrystalline, amorphous or porous
• CPC Class Codes: H01L 33/50 Wavelength conversion elements
• CPC Class Codes: H01L 33/502 Wavelength conversion materials
• CPC Class Codes: H01L 33/58 Optical field-shaping elements
• CPC Class Codes: H01S 5/0087 for illuminating phosphorescent or fluorescent materials, e.g. using optical arrangements specifically adapted for guiding or shaping laser beams illuminating these materials
• CPC Class Codes: H01S 5/02212 Can-type, e.g. TO-CAN housings with emission along or parallel to symmetry axis
• CPC Class Codes: H01S 5/32341 blue laser based on GaN or GaP
• CPC Class Codes: Y02B 20/00 Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps

Abstract

A light emitting device 1 includes: a substrate 30; and a phosphor layer 40 composed in such a manner that a large number of phosphor particles 60 are adhered onto a flat surface 32 of the substrate 30. At least one of the phosphor particles 60 is a polyhedral phosphor particle 65 that is monodispersed, is derived from a crystal structure of garnet and has facets, and a median particle size D₅₀ of the polyhedral phosphor particle 65 is 30 μm or more and a maximum thickness of the phosphor layer 40 or less. It is preferable that at least one of the phosphor particles 60 adhered onto the flat surface 32 of the substrate 30 is the polyhedral phosphor particle 65 that is monodispersed, is derived from the crystal structure of the garnet, and has the facets.

Claims

1. A wavelength converter comprising:

a substrate; and

a phosphor layer,

wherein the phosphor layer includes a plurality of polyhedral phosphor particles, each of the polyhedral phosphor particles is monodispersed, is derived from a crystal structure of garnet and has facets,

a median particle size D₅₀ of the plurality of polyhedral phosphor particles is 30 μ

m or more,

the facets of the polyhedral phosphor particles and a flat surface of the substrate are substantially parallel to each other, and

heat generated in the phosphor particles contained in the phosphor layer propagates to the substrate via the facets.

2. The wavelength converter according to claim 1, wherein a plurality of portions where the facets of the polyhedral phosphor particles and the flat surface of the substrate are adhered to each other in a surface contact manner are provided.

3. The wavelength converter according to claim 1, wherein the facets of the adjacent polyhedral phosphor particles are adhered to one another in a surface contact manner.

4. The wavelength converter according to claim 1, wherein the median particle size D₅₀ of the polyhedral phosphor particle is in the range of the maximum thickness of the phosphor layer or less.

5. The wavelength converter according to claim 1, further comprising:

substrate-phosphor adhesion portions which adhere the flat surface of the substrate and the facets of the polyhedral phosphor particles in the phosphor layer to each other,

wherein the substrate-phosphor adhesion portions are made of an inorganic binding agent.

6. The wavelength converter according to claim 1, further comprising:

inter-phosphor particle adhesion portions which adhere the facets of the adjacent polyhedral phosphor particles to one another,

wherein the inter-phosphor particle adhesion portions are made of an inorganic binding agent.

7. The wavelength converter according to claim 5, wherein the inorganic binding agent is nanoparticles with a median particle size D50 of 1 nm or more and 100 nm or less.

8. The wavelength converter according to claim 5, wherein the inorganic binding agent includes at least one inorganic oxide selected from the group consisting of Al₂O₃, ZnO, MoO₃ and ZnMoO₄.

9. The wavelength converter according to claim 1, wherein the wavelength converter is an inorganic wavelength converter.

10. The wavelength converter according to claim 1, wherein the phosphor layer contains small particles smaller in particle size than the phosphor particles.

11. The wavelength converter according to claim 10, wherein the small particles is made of an inorganic material.

12. The wavelength converter according to claim 10, wherein the inorganic material constituting the small particles is a phosphor, a translucent substance other than the phosphor, or a light reflecting substance other than the phosphor.

13. The wavelength converter according to claim 10, wherein the inorganic material constituting the small particles is the phosphor having the same composition as the phosphor particles contained in the phosphor layer.

14. The wavelength converter according to claim 1, wherein the substrate is a transparent substrate or a metal substrate.

15. A light emitting device comprising the wavelength converter according to claim 1.

16. The light emitting device according to claim 15, further comprising:

a solid-state light emitting element radiates primary light, wherein the wavelength converter receives the primary light and radiate light.

17. The light emitting device according to claim 16, wherein the primary light is a laser beam.

18. The light emitting device according to claim 15, wherein the light emitting device is a laser lighting device or a laser projector.

19. The wavelength converter according to claim 1, wherein in at least one of the polyhedral phosphor particles, an area of at least one of the facets exceeds 200 μ

m².