Wavelength conversion component with scattering particles

• US 8,614,539 B2
• Filed: 10/13/2011
• Issued: 12/24/2013
• 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:
  US13/273,215
• Publication Number:
  US 20120087104A1
• Time in Patent Office: 803 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 9/64 using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
• 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 has at least one photoluminescence material and a light scattering material, where the light scattering material has an average particle size that is selected such that the light scattering material will scatter excitation light from a radiation source relatively more than the light scattering material will scatter light generated by the photoluminescence material.

Claims

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

at least one photoluminescence material; and

a light scattering material, wherein the light scattering material has an average particle size that is selected such that the light scattering material will scatter excitation light from a radiation source relatively more than the light scattering material will scatter light generated by the at least one photoluminescence material,

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

wherein the light scattering material scatters the blue light at least twice as much as light generated by the at least one photoluminescence material.

2. The component of claim 1, wherein the light scattering material has an average particle size that is less than about 150 nm.

3. 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.

4. The component of claim 1 wherein the at least one photoluminescence material is located in a wavelength conversion layer and the light scattering material is located in a diffusing layer.

5. The component of claim 4, wherein the wavelength conversion layer and the light diffusing layer are in direct contact with each other.

6. The component of claim 4, 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.

7. The component of claim 6, 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.

8. The component of claim 6, wherein the weight loading of light scattering material to binder selected from the group consisting of:

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

9. The component of claim 4, 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 4 in which the wavelength conversion layer and the light diffusing layer comprises planar shapes.

11. The component of claim 4 in which the light diffusing layer comprises a dome or elongated dome shape.

12. The component of claim 11 in which the wavelength conversion layer fills a volume formed beneath the dome or elongated dome shapes.

13. The component of claim 1, wherein both the at least one photoluminescence material and the light scattering material are located in a wavelength conversion layer.

14. 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.

15. The component of claim 1, wherein the at least one photoluminescence material is deposited onto 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, wherein the excitation light comprises ultraviolet light.

17. The component of claim 16, wherein the light scattering material has an average particle size that is less than about 100 nm.

18. A light emitting device, comprising:

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

a wavelength conversion component comprising;

at least one photoluminescence material; and

a light scattering material, wherein the light scattering material has an average particle size that is selected such that the light scattering material will scatter excitation light from the at least one solid-state light emitter relatively more than the light scattering material will scatter light generated by the at least one photoluminescence material,

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

wherein the light scattering material scatters the blue light at least twice as much as light generated by the at least one photoluminescence material.

19. The device of claim 18, 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.

20. The device of claim 18 in which the average particle size of the light scattering material is selected to improve an OFF state white appearance of the light emitting device.

21. The device of claim 18 in which the average particle size of the light scattering material is selected to obtain substantially uniform color for emitted light from the light emitting device for emission angles over a ±

60°

range from an emission axis.

22. The device of claim 21, 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%.

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

24. The device of claim 18 in which the wavelength conversion layer and the light diffusing layer comprises planar shapes.

25. The device of claim 18 in which the light diffusing layer comprises a dome or elongated dome shape.

26. 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

at least one photoluminescence material; and

a light scattering material, wherein the light scattering material has an average particle size that is selected such that the light scattering material will scatter excitation light from the plurality of solid-state light emitters relatively more than the light scattering material will scatter light generated by the at least one photoluminescence material,

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

wherein the light scattering material scatters the blue light at least twice as much as light generated by the at least one photoluminescence material.

27. 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

at least one photoluminescence material; and

a light scattering material, wherein the light scattering material has an average particle size that is selected such that the light scattering material will scatter excitation light from the one or more solid-state light emitters relatively more than the light scattering material will scatter light generated by the at least one photoluminescence material,

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

wherein the light scattering material scatters the blue light at least twice as much as light generated by the at least one photoluminescence material.

28. 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

at least one photoluminescence material; and

a light scattering material, wherein the light scattering material has an average particle size that is selected such that the light scattering material will scatter excitation light from the one or more solid-state light emitters relatively more than the light scattering material will scatter light generated by the at least one photoluminescence material,

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

wherein the light scattering material scatters the blue light at least twice as much as light generated by the at least one photoluminescence material.