This invention relates to light sources and the manufacturing of light sources. In particular, this invention relates to light sources and “light engines” that are used for specific light tasks including, for example, flash lights, automotive lights, streets and public areas as well as industrial area lighting and medical illumination.
With the development of the Light Emitting Diode (LED) for use in the lighting industry, the opportunity for energy savings continues to be significant for individuals and society as a whole. A major hurdle impeding the realization of energy savings, however, is the cost of installation or manufacturing. In particular, many of the new technological improvements which greatly improve the luminous efficacy of white LEDs come with disadvantages in the manufacturing process.
In the manufacturing of a common white light LED, a phosphor powder blend is normally mixed with an encapsulant and deposited as a layer onto the surface of an emitter junction. Many emitter junctions are narrow wavelength band blue or near ultraviolet (UV) diodes, with a Full Width at Half Maximum (FWHM) of only 40 nm. The phosphor blend is created to absorb the blue or UV wavelengths and reemit broadband green to red wavelengths. The ratio of blue absorption to secondary green to red emissions determines the color temperature of the emitted white light. This is a straightforward process and as such any improvements to increase the luminosity output add complications to this process which can increase the manufacturing cost.
Failures that plague the above approach include heat degradation of the phosphor due to its proximity to the emitter junctions. The emitter junctions run at relatively high temperatures (>70 deg C.) against an ambient background (25 deg C.). The encapsulant degrades with higher temperatures, often resulting in discoloration and inefficient transmitters in the blue or the visible wavelength region. Additionally, the encapsulant acts as a thermal blanket on top of the emitter junctions causing a further loss of efficiency. Close proximity of the phosphor layer to the emitter junctions also creates an additional loss of white luminosity, as efficient emitters by definition (thermo-dynamic blackbodies) must also be efficient absorbers, thus white light generated near the emitters is lost energy.
There exists another limitation to the above approach: the relatively small area of emission. This creates an increase in luminosity but spreads the light output over a small cone angle, thus creating a very high brightness. Such brightness levels can pose a threat to the human vision system and can contribute to migraines, seizures, and temporary washout of the human eye. Yet another limitation to the above approach is that it is not directly scalable. It is not an easy task to increase luminosity by adding more emitter junctions and thicker layers of phosphor. Such endeavors increase the heat load in a non-linear way while adding more of the “blanket” effect from the phosphor encapsulant.
The aforementioned problems are overcome by the present invention which includes a volumetric light emitter that can be manufactured independently of an emitter junction. The volumetric light emitter includes a first conic reflector including an aperture for a light source or an emitter junction, a second conic reflector opposite the first conic reflector for collimating light emitted by the light source, and a volumetric light conversion element extending between at least a portion of the first reflector and at least a portion of the second reflector.
In one aspect of the invention, the light conversion element includes phosphor particles dispersed in a resin to convert light emitted by the light source from a first wavelength to a second wavelength, the second wavelength being longer than the first wavelength. As disclosed, the light conversion element is substantially solid, and includes an annular outer surface, wherein light is emitted through the annular outer surface in a generally toroidal pattern. Additionally, the light conversion element preferably includes a cylindrical portion or a frusto-conical portion being coaxial with the first and second conic reflectors.
In another aspect of the invention, the first conic reflector is elliptical and the second conic reflector is parabolic. The volumetric light emitter includes a negative mirror adjacent the vertex of the second conic reflector. Additionally, the volumetric light emitter includes an elliptical element adjacent the first conic reflector, wherein the first conic reflector and the elliptical element define a coextensive aperture for the light source.
The volumetric light emitter can be optically bonded to one or more emitter junctions as a final step, thus creating a simple volumetric light engine wherever a light filament or arc may be used. This invention acts as a bridging technology between LED junction manufacturers and luminaire manufacturers, which delivers the lighting requirements to the end user. This allows for a common design to be implemented with a variety of LED junctions and heat sink arrangements. Another benefit of this invention lies in integrating three specific optical tasks into one simple and manufacturable form. The three optical tasks are: 1) light gathering and placement from emitter junctions, 2) improving utilization and containment of pump light, and 3) down conversion and emission of white light. This integration opens up new designs for luminaires and possesses the benefit of ease of retrofitting older structures with LED sources.
These and other advantages and features of the invention will be more fully understood and appreciated by reference to the drawings and the description of the current embodiments.
A main focus of conventional LED research is to maximize luminosity while reducing the energy consumption, i.e., luminous efficacy. Even though this seems to be the best path to success, it is fraught with gains in luminosity which are not practical for the mass production environment that white LED-based luminaries will need to be at. A wiser approach is to look at the costs of producing white luminosity. These costs break down to operational costs and implementation costs. It is the great savings in operational costs to our society that is driving the development of this technology. However it is the implementation cost that becomes the biggest barrier to moving forward. The present invention addresses this cost barrier—the implementation cost barrier. This is the problem we as a society are trying to solve; the maximization of white luminosity while reducing the number of manufacturing steps involved in reaching the end use luminaire. As explained herein, the present invention can perform three distinct optical functions in a single molded component. The first optical task is to gather the light from the LED junction source and convert it to a more usable format. The second optical task is to create a gain function in the intensity of the Deep Blue Light (DBL) while constraining the DBL losses. The third optical task is to create an optical environment for best down conversion efficiency. As explained below, the three optical functions lead to improvements on seven parameters which cause the luminosity to produce high performance and which offer a simple manufacturable design. Due to its single piece layout, the present invention also lends itself to cost effective manufacturing.
With the above optical tasks in mind, the present invention provides a volumetric light emitter which constrains DBL into a light conversion chamber to thereby control losses and maximize the probability of white light generation via phosphorescence. This is achieved, in part, by making use of a concept from laser physics: the resonant cavity. The purpose of a resonant cavity is to confine the DBL such that the only loss in the DBL is from the excitation of the phosphors within the resonator structure. The Applicant acknowledges that the requirements of an operational laser resonant cavity—High Q status, cavity length=N×Wavelength, Spectral Line width of 1 nm, etc—cannot be achieved from an LED source. The terms ‘resonant cavity’ and ‘resonant structure’ are used as a descriptor in creating a visual reference for describing the present invention. This resonant structure, or Constrained Folded Path Cavity (CFPC), possesses reflectors at opposite ends. One purpose of the CFPC is to cause the DBL to repeat its path of propagation a number of times over, while reducing the number of exit paths that allow the DBL to escape. Current repeat propagations vary between 4 and 40, depending on the resonant model chosen, not in the thousands or millions as required for a laser resonant cavity. This will increase the intensity of DBL while keeping it contained within a known volume. One embodiment of the resonant structure is the hemi-confocal cavity structure as shown in
In addition to constraining DBL in a resonant cavity, the volumetric light emitter radiates Down-Converted White Light (DCWL) in a toroidal or a spherical pattern. This is accomplished by using a remote phosphor blended into a resin material, which forms a three-dimensional or volumetric light conversion element in the resonant structure of the CFPC, thus creating a volumetric white light radiator In the present embodiment, a phosphor, such as EY4453 by Internatix, is premixed into an acrylic, polycarbonate, Nylon, or polystyrene resin for injection molding, such as Nylon 6/66 by BASF (marketed as ULTRAMID®). The phosphor-doped light conversion element can optionally be molded with the curvatures of the reflectors of the CFPC. Additionally, the density of the phosphor is such that the volumetric light conversion element is translucent to the DBL, not opaque. For example, if the DBL will make 6 reflections within the CFPC, then it is desirable to absorb 16.67% per pass with total absorption at 100% for 6 reflections. It is also possible to utilize this technology with castings, extruding, press forms, or machining to achieve the desired form.
The volumetric white light emitter of the present invention may also be used in conjunction with an optical coupler, such as the optical coupler disclosed in U.S. patent application Ser. No. 12/405,398 to Bourget, filed on Mar. 17, 2009, and titled “High Efficiency Optical Coupler,” which is incorporated herein by reference. In particular, a High Efficiency Optical Coupler (HEOC) can convert a Lambertian source into a non-Lambertian radiator to reduce the Numerical Aperture (N.A.) of the source light. This improves the “usability” of the DBL. By choosing the correct radii and conics, a bi-modal intensity pattern output can be created, and the HEOC can to collect up to 98% of all DBL and place it where it is most likely that blue photons will interact with phosphor materials. Accordingly, the present invention combines a HEOC, a constrained folded path cavity, and a toroidal radiator into a single element. Several benefits can accrue from the present invention:
(1) more efficient transfer (up to 98%) of DBL into the phosphorescence region;
(2) “resonant” coupling within the phosphorescence region for multi-pass intensity gain of DBL;
(3) reduced white light loss due to reabsorption at the emission junction(s);
(4) less complex heat sink and heat sink costs due to heat flow improvement attributed to the flexibility of location of the emitter junction(s);
(5) improved temperature stability and less temperature light output degradation due to remote phosphor effect;
(6) fine tuning of chromaticity based on cavity length; and
(7) reduced manufacturing loss yields due to fewer mechanical operations at the emitter junction(s).
Accordingly, the embodiments of present invention provide multiple improvements.
A volumetric white light emitter in accordance with an embodiment of the present invention is illustrated in
As explained below, the volumetric white light emitter 20 can be adapted to accommodate a specific LED based on its peak emission wavelength. For example, the volumetric white light emitter 20 of the present embodiment is configured to down-convert DBL light from an LED junction having a DBL emission wavelength of 455 nm. The volumetric light conversion element 26 includes a phosphor chosen with a main radiation peak of 570 nm (Yellow) and a FWHM of 90 nm—a typical “off the shelf” phosphor material. The design goal is to convert at least 80% of the emitted blue light into the yellow light output. The blending of the remaining blue light and the phosphorescent yellow light creates to the human eye a lower Color Rendering Index (CRI) of white light (while lower CRI light is not accurate for color measurement, it is adequate for many general illumination applications). For a single junction system with an emission area of 1.3 mm sq. having 1.14 mm on a side, typical operational parameters include an operating current (Iop) of 350 mAmps with a voltage drop of 3.4 Vdc for a power consumption of 1.2 Watts. A typical output conversion efficiency of 25% yields a radiant power of 0.3 Watts. Expressed as luminosity, the value at 455 nm with 36.5 lm/Watt×0.3 Watts equals 11 lumens of blue light.
The second conic reflector 24 is selected to have a diameter about ten times larger than the baseline of the emitter. In the present embodiment, this sets the operational diameter of the second conic reflector 24 at 11. mm. For a surface mount junction, the angle for the FWHM of the Lambertian intensity distribution is typically 60 degrees, corresponding to an N.A. of 0.866. For light propagating through an acrylic resin medium (Index of Refraction=1.497), this same N.A. creates the angle of intensity of 35.4 degrees. This angle is used in combination with the operational diameter to calculate the radius of the second reflector 24 and the cavity length. As noted above, one purpose of the second conic reflector 24 is to collimate the reflected rays and direct them toward the first conic reflector 22. From the Mirror Formula, a mirror's radius being equal to twice the focal length, sets the radius of the second conic reflector 24 equal to the twice the length from the emitter junctions to the second conic reflector 24:
Radius of Second Reflector=2×(11.4 mm/2)/Tan 35.4°=16.0 mm.
This suggests that the cavity volume be roughly 0.82 cm3 from the following formula:
V=Pi×R2×L
While the second conic reflector 24 is parabolic with a numerical conic value of −1.00, it is also possible to make variations in the conic, thus changing the shape from hyperbolic to spherical based on the desired cavity constraints.
The purpose of the first conic reflector 22 is to gather the collimated light from the second conic reflector 24 and bring it to a focal plane. It is desirable, however, to set the focal plane to intersect a point on the second conic reflector 24 such that the ray path of the DBL crosses the main Z axis 42 and retraces its path back to the emitter junctions. The choice here is how many reflective paths to have between the first and second conic reflectors 22, 24. In the current embodiment we have 6 reflections as illustrated in
It is preferable to add a small negative element, for example a convex mirror 32, placed at or adjacent the vertex 34 of the second conic reflector 24 to diverge the near axial propagated light emitted from the emitter junction(s). Without this negative element 32, reflected DBL off of the second conic reflector 24 can retrace its path along the main axis 42 and intersect the junction(s) surface. The diameter of the negative element 32 will normally not be greater than one-third of the diameter of the second conic reflector 24. As shown in
The luminous output spectral distribution of the volumetric white light generator of
A folded spherical cavity 50 in accordance with another embodiment of the present invention is shown in
A folded transverse cavity 70 in accordance with an embodiment of the present invention is shown in
A folded confocal cavity 90 in accordance with an embodiment of the present invention is shown in
The above embodiments include a volumetric light emitter that can be manufactured independently of the emitter junction or other light source. The volumetric light emitter can be optically bonded to the emitter junctions or other light source as a final step, thus creating a simple volumetric light engine to radiate down-converted white light in a toroidal, spherical, or other pattern.
The above descriptions are those of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as set forth in the following claims, which are to be interpreted in accordance with the principles of patent law including the Doctrine of Equivalents.
Number | Name | Date | Kind |
---|---|---|---|
3934148 | Collins | Jan 1976 | A |
4241382 | Daniel | Dec 1980 | A |
5347433 | Sedlmayr | Sep 1994 | A |
5572375 | Crabtree, IV | Nov 1996 | A |
5803579 | Turnbull et al. | Sep 1998 | A |
5903403 | Williamson | May 1999 | A |
6155699 | Miller et al. | Dec 2000 | A |
6350041 | Tarsa et al. | Feb 2002 | B1 |
6522065 | Srivastava et al. | Feb 2003 | B1 |
6710544 | Schliep et al. | Mar 2004 | B2 |
6759803 | Sorg | Jul 2004 | B2 |
6782027 | Cox et al. | Aug 2004 | B2 |
6791259 | Stokes et al. | Sep 2004 | B1 |
6806509 | Yoshino et al. | Oct 2004 | B2 |
6833565 | Su et al. | Dec 2004 | B2 |
6921929 | LeBoeuf et al. | Jul 2005 | B2 |
6928099 | Ledentsov et al. | Aug 2005 | B2 |
6937791 | Guy | Aug 2005 | B2 |
6960872 | Beeson et al. | Nov 2005 | B2 |
7005679 | Tarsa et al. | Feb 2006 | B2 |
7040774 | Beeson et al. | May 2006 | B2 |
7070300 | Harbers et al. | Jul 2006 | B2 |
7091653 | Ouderkirk et al. | Aug 2006 | B2 |
7108386 | Jacobson et al. | Sep 2006 | B2 |
7286296 | Chaves et al. | Oct 2007 | B2 |
7316497 | Rutherford et al. | Jan 2008 | B2 |
7378686 | Beeson et al. | May 2008 | B2 |
7497581 | Beeson et al. | Mar 2009 | B2 |
7521862 | Mueller et al. | Apr 2009 | B2 |
7525127 | Hattori et al. | Apr 2009 | B2 |
7573189 | Juestel et al. | Aug 2009 | B2 |
7618157 | Galvez et al. | Nov 2009 | B1 |
7665865 | Hulse et al. | Feb 2010 | B1 |
20020180351 | McNulty et al. | Dec 2002 | A1 |
20030016539 | Minano et al. | Jan 2003 | A1 |
20030034985 | Needham Riddle et al. | Feb 2003 | A1 |
20040070855 | Benitez et al. | Apr 2004 | A1 |
20040159900 | Ouderkirk et al. | Aug 2004 | A1 |
20040228131 | Minano et al. | Nov 2004 | A1 |
20060034084 | Matsuura et al. | Feb 2006 | A1 |
20060066192 | Beeson et al. | Mar 2006 | A1 |
20060203468 | Beeson et al. | Sep 2006 | A1 |
20070064407 | Huang et al. | Mar 2007 | A1 |
20070103912 | Namii | May 2007 | A1 |
20070278512 | Loh et al. | Dec 2007 | A1 |
20070279907 | Goto et al. | Dec 2007 | A1 |
20070297179 | Leung et al. | Dec 2007 | A1 |
20080030993 | Narendran et al. | Feb 2008 | A1 |
20080094829 | Narendran et al. | Apr 2008 | A1 |
20080117500 | Narendran et al. | May 2008 | A1 |
20080218992 | Li | Sep 2008 | A1 |
20080310158 | Harbers et al. | Dec 2008 | A1 |
20090225529 | Falicoff et al. | Sep 2009 | A1 |
20090262516 | Li | Oct 2009 | A1 |
20090278146 | Maeda | Nov 2009 | A1 |
20100109036 | Chen et al. | May 2010 | A1 |
20100165599 | Allen | Jul 2010 | A1 |
20100239207 | Bourget | Sep 2010 | A1 |
20100290226 | Harbers et al. | Nov 2010 | A1 |
Number | Date | Country |
---|---|---|
2006003569 | Jan 2006 | WO |
Entry |
---|
R. Leutz, L. Fu, and H. Ries, “Carambola optics for recycling of light,” Appl. Opt. 45, 2572-2575 (2006). |
International Search Report and Written Opinion, International Application No. PCT/US2011/021465, International Filing Date Jan. 17, 2011. |
Number | Date | Country | |
---|---|---|---|
20110215707 A1 | Sep 2011 | US |