Wavelength conversion component with a diffusing layer

• US 8,604,678 B2
• Filed: 10/13/2011
• Issued: 12/10/2013
• Est. Priority Date: 10/05/2010
• Status: Active Grant

• Current Assignee: Feit Electric Company Incorporated
• Original Assignee: Intematix Corporation
• Inventors: Dai, Bing, Yuan, Xianglong, Wang, Gang, Edwards, Charles, Caruso, James
• Primary Examiner(s): Bowman, Mary Ellen
• Application Number:
  US13/273,212
• Publication Number:
  US 20120087103A1
• Time in Patent Office: 789 Days
• Field of Search: 313/112, 313/498, 313/501, 313/512, 257/98, 438/27
• US Class Current: 313/112
• CPC Class Codes: F21V 13/08 the elements being filters or photoluminescent elements and reflectors
• CPC Class Codes: F21V 5/10 comprising photoluminescent material
• CPC Class Codes: F21V 9/30 Elements containing photoluminescent material distinct from or spaced from the light source shades F21V1/17; globes, bowls or cover glasses F21V3/08, F21V3/12; refractors F21V5/10; reflectors F21V7/26, F21V7/30; elements with provision for controlling the spectral properties or intensity F21V9/40
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A light emitting device comprises at least one solid-state light source (LED) operable to generate excitation light and a wavelength conversion component located remotely to the at least one source and operable to convert at least a portion of the excitation light to light of a different wavelength. The wavelength conversion component includes a light transmissive substrate having a wavelength conversion layer comprising particles of at least one photoluminescence material and a light diffusing layer comprising particles of a light diffractive material. This approach of using the light diffusing layer in combination with the wavelength conversion layer solves the problem of variations or non-uniformities in the color of emitted light with emission angle.

Claims

1. A wavelength conversion component for a light emitting device comprising:

a wavelength conversion layer comprising particles of at least one photoluminescence material; and

a light diffusing layer comprising particles of a light scattering material,

wherein the light diffusing layer improves an off-state white appearance of the wavelength conversion component;

wherein the wavelength conversion component is configured such that in operation a portion of excitation light comprising blue light having a wavelength of greater than or equal to 440 nm generated by the light emitting device is emitted through the wavelength conversion component to contribute to a final visible emission product.

2. The component of claim 1, wherein the wavelength conversion layer and the light diffusing layer are in direct contact with each other.

3. The component of claim 1, wherein the wavelength conversion layer comprises a mixture of the at least one phosphor material and a light transmissive binder and the light diffusing layer comprises a mixture of the light scattering material and the light transmissive binder.

4. The component of claim 3, wherein the wavelength conversion layer further comprises a second light scattering material.

5. The component of claim 4, wherein the light scattering material and the second light scattering material have different material properties.

6. The component of claim 3, wherein the light transmissive binder comprises a curable liquid polymer selected from the group consisting of:

a polymer resin, a monomer resin, an acrylic, an epoxy, a silicone and a fluorinated polymer.

7. The component of claim 3, wherein the weight loading of light scattering material to binder selected from the group consisting of:

7% to 35% and 10% to 20%.

8. The component of claim 1, wherein the light scattering material has an average particle size in a range selected from the group consisting of:

1 μ

m to 50 μ

m and 10 μ

m to 20 μ

m.

9. The component of claim 1, wherein the wavelength conversion and light diffusing layers are deposited using a method selected from the group consisting of:

screen printing, slot die coating, spin coating, roller coating, drawdown coating and doctor blading.

10. The component of claim 1, wherein the light scattering material is selected from the group consisting of:

titanium dioxide, barium sulfate, magnesium oxide, silicon dioxide and aluminum oxide.

11. The component of claim 1, wherein the light scattering material has an average particle size that is selected such that the light scattering material will scatter the excitation light relatively more than the light scattering material will scatter light generated by the at least one photoluminescence material.

12. The component of claim 11, wherein the light scattering material scatters the excitation light at least twice as much as light generated by the at least one photoluminescence material.

13. The component of claim 11, wherein the excitation light comprises blue light.

14. The component of claim 13, wherein the light scattering material has an average particle size that is less than about 150 nm.

15. The component of claim 1, wherein the light diffusing layer is deposited on a light transmissive substrate, and the light transmissive substrate is selected from the group consisting of:

a polycarbonate, an acrylic and a glass.

16. The component of claim 1 in which the wavelength conversion layer and the light diffusing layer comprises planar shapes.

17. The component of claim 1 in which the light diffusing layer comprises a dome or elongated dome shape.

18. The component of claim 17 in which the wavelength conversion layer fills a volume formed beneath the dome or elongated dome shapes.

19. A light emitting device, comprising:

at least one solid-state light emitter operable to generate excitation light; and

a wavelength conversion component comprising;

a wavelength conversion layer excitable by the excitation light, wherein the wavelength conversion layer comprises particles of at least one photoluminescence material; and

a light diffusing layer comprising particles of a light scattering material,

wherein the light diffusing layer improves an OFF state white appearance of the wavelength conversion component;

wherein the wavelength conversion component is configured such that in operation a portion of light comprising blue light having a wavelength of greater than or equal to 440 nm generated by the at least one solid-state light emitter is emitted through the wavelength conversion component to contribute to a final visible emission product.

20. The device of claim 19, wherein the light emitting device is selected from the group consisting of:

downlights, light bulbs, linear lamps, lanterns, wall lamps, pendant lamps, chandeliers, recessed lights, track lights, accent lights, stage lighting, movie lighting, street lights, flood lights, beacon lights, security lights, traffic lights, headlamps, taillights, and signs.

21. The device of claim 19 in which the light scattering material within the light diffusing layer corresponds to an average particle size that improves the OFF state white appearance of the wavelength conversion component.

22. The device of claim 19 in which the light diffusing layer is configured to obtain substantially uniform color for emitted light from the light emitting device for emission angles over a ±

60°

range from an emission axis.

23. The device of claim 22, wherein a weight loading of the light scattering material to a binder selected from the group consisting of:

7% to 35% and 10% to 20%.

24. The device of claim 19, wherein the light scattering material has an average particle size in a range selected from the group consisting of:

1 μ

m to 50 μ

m and 10 μ

m to 20 μ

m.

25. The device of claim 19 in which the wavelength conversion layer and the light diffusing layer comprises planar shapes.

26. The device of claim 19 in which the light diffusing layer comprises a dome or elongated dome shape.

27. A linear lamp comprising:

an elongate housing;

a plurality of solid-state light emitters housed within the housing and configured along the length of the housing; and

an elongate wavelength conversion component remote to the plurality of solid-state light emitters and configured to in part at least define a light mixing chamber,

wherein the elongate wavelength conversion component comprises a wavelength conversion layer comprising particles of at least one photoluminescence material and a light diffusing layer comprising particles of a light scattering material,

wherein the light diffusing layer improves an off-state white appearance of the elongate wavelength conversion component;

wherein the elongate wavelength conversion component is configured such that in operation a portion of light comprising blue light having a wavelength of greater than or equal to 440 nm generated by the plurality of solid-state light emitters is emitted through the wavelength conversion component to contribute to a visible final emission product.

28. A downlight comprising:

a body comprising one or more solid-state light emitters, wherein the body is configured to be positioned within a downlighting fixture such that the downlight emits light in a downward direction; and

a wavelength conversion component remote to the one or more solid-state light emitters and configured to in part at least define a light mixing chamber,

wherein the wavelength conversion component comprises a wavelength conversion layer comprising particles of at least one photoluminescence material and a light diffusing layer comprising particles of a light scattering material,

wherein the light diffusing layer improves an off-state white appearance of the wavelength conversion component;

wherein the wavelength conversion component is configured such that in operation a portion of light comprising blue light having a wavelength of greater than or equal to 440 nm generated by the one or more solid-state light emitters is emitted through the wavelength conversion component to contribute to a final visible emission product.

29. A light bulb comprising:

a connector base configured to be inserted in a socket to form an electrical connection for the light bulb;

a body comprising one or more solid-state light emitters;

a wavelength conversion component having a three dimensional shape that is configured to enclose the one or more solid-state light emitters and to in part at least define a light mixing chamber,

wherein the wavelength conversion component comprises a wavelength conversion layer comprising particles of at least one photoluminescence material and a light diffusing layer comprising particles of a light scattering material,

wherein the light diffusing layer improves an off-state white appearance of the wavelength conversion component;

wherein the wavelength conversion component is configured such that in operation a portion of light comprising blue light having a wavelength of greater than or equal to 440 nm generated by the one or more solid-state light emitters is emitted through the wavelength conversion component to contribute to a final visible emission product.