Wavelength conversion component

• US 8,610,341 B2
• Filed: 10/13/2011
• Issued: 12/17/2013
• 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:
  US13/273,217
• Publication Number:
  US 20120087105A1
• Time in Patent Office: 796 Days
• Field of Search: 313/112, 313/498, 313/501, 313/512, 257/98, 438/27
• US Class Current: 313/112
• CPC Class Codes: F21K 9/232 specially adapted for generating an essentially omnidirectional light distribution, e.g. with a glass bulb
• CPC Class Codes: F21K 9/27 Retrofit light sources for lighting devices with two fittings for each light source, e.g. for substitution of fluorescent tubes
• CPC Class Codes: F21K 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• CPC Class Codes: F21S 8/02 of recess-mounted type, e.g. downlighters specially adapted for vehicle exteriors F21S41/00-F21S45/00
• CPC Class Codes: F21V 13/08 the elements being filters or photoluminescent elements and reflectors
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 3/00 Globes; Bowls; Cover glasses with refracting properties F21V5/00; with reflecting properties F21V7/00; characterised by cooling arrangements F21V29/506
• CPC Class Codes: F21V 3/061 the material being glass
• CPC Class Codes: F21V 3/062 the material being plastics
• CPC Class Codes: F21V 3/12 the coatings comprising photoluminescent substances
• CPC Class Codes: F21V 9/32 characterised by the arrangement of the photoluminescent material
• CPC Class Codes: F21Y 2105/16 square or rectangular, e.g. for light panels
• CPC Class Codes: F21Y 2105/18 annular; polygonal other than square or rectangular, e.g. for spotlights or for generating an axially symmetrical light beam
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: F21Y 2115/30 Semiconductor lasers
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 2933/0091 Scattering means in or on the semiconductor body or semiconductor body package H01L33/22 takes precedence
• CPC Class Codes: H01L 33/50 Wavelength conversion elements

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 diffusing layer having particles of a light scattering material, where the light diffusing layer has a shape with an inner surface that defines an interior volume, and a wavelength conversion layer having particles of at least one photoluminescence material within the interior volume.

Claims

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

a light diffusing layer comprising particles of a light scattering material, wherein the light diffusing layer has a shape with an inner surface that defines an interior volume;

a wavelength conversion layer comprising particles of at least one photoluminescence material within the interior volume,

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

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 shape comprises a dome shape or an elongated dome shape.

3. The component of claim 1, wherein the wavelength conversion layer substantially fills the interior volume of the shape of the light diffusing layer.

4. The component of claim 1, wherein the wavelength conversion layer comprises the same shape as the light diffusing layer.

5. 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.

6. The component of claim 5, wherein the wavelength conversion layer further comprises a second light scattering material.

7. The component of claim 6, wherein the light scattering material and the second light scattering material have different material properties.

8. The component of claim 5, 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.

9. The component of claim 5, wherein the weight loading of light scattering material to binder selected from the group consisting of:

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

10. 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.

11. The component of claim 1, wherein the light diffusing layer is formed using a molding process.

12. The component of claim 11, wherein the molding process comprises a vacuum molding or an injection molding process.

13. The component of claim 11, wherein the wavelength conversion layer is formed using a molding process.

14. The component of claim 11, wherein the wavelength conversion layer is formed by depositing phosphor material with a binder material into the interior volume of the light diffusing layer.

15. 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.

16. 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 excitation light relatively more than the light scattering material will scatter light generated by the at least one photoluminescence material.

17. The component of claim 16, wherein the light scattering material scatters the excitation light at least twice as much as light generated by the at least one photoluminescence material.

18. The component of claim 16, wherein the excitation light comprises blue light.

19. The component of claim 18, wherein the light scattering material has an average particle size that is less than about 150 nm.

20. The component of claim 16, wherein the excitation light comprises ultraviolet light.

21. The component of claim 18, wherein the light scattering material has an average particle size that is less than about 100 nm.

22. The component of claim 1, wherein the 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.

23. A light emitting device, comprising:

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

a wavelength conversion component comprising;

a light diffusing layer comprising particles of a light scattering material, wherein the light diffusing layer has a shape with an inner surface that defines an interior volume;

a wavelength conversion layer comprising particles of at least one photoluminescence material within the interior volume that is excitable by the excitation light,

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.

24. The device of claim 23, 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.

25. The device of claim 23 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.

26. The device of claim 23, wherein the light scattering material has an average particle size in a range selected from the group consisting of:

1 μ

m to 50 m and 10 μ

m to 20 μ

m.

27. The device of claim 23, wherein the excitation light comprises blue light and the light scattering material scatters the blue light at least twice as much as light generated by the at least one photoluminescence material.

28. The device of claim 27, wherein the light scattering material has an average particle size that is less than about 150 nm.

29. 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 light diffusing layer comprising particles of a light scattering material, wherein the light diffusing layer has a shape with an inner surface that defines an interior volume; and

a wavelength conversion layer comprising particles of at least one photoluminescence material within the interior volume,

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.

30. 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 light diffusing layer comprising particles of a light scattering material, wherein the light diffusing layer has a shape with an inner surface that defines an interior volume; and

a wavelength conversion layer comprising particles of at least one photoluminescence material within the interior volume,

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.

31. 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 light diffusing layer comprising particles of a light scattering material, wherein the light diffusing layer has a shape with an inner surface that defines an interior volume; and

a wavelength conversion layer comprising particles of at least one photoluminescence material within the interior volume,

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.