This claims priority to German patent application no. 10 2022 123 050.3, filed Sep. 9, 2022, which is incorporated herein by reference.
The present invention relates to an illumination device, and, more particularly, to an illumination device with a light conversion element.
In laser-pumped light conversion elements, excitation light (primary radiation) is coupled into a luminescence converter. The useful light (secondary radiation) generated by photoluminescence is decoupled again, by which a light source is provided.
One example is garnet-based converters having cerium as the active element (for example, Ce:YAG, Ce:LuAG), wherein these can be operated as static converters in remission geometry with laser excitation. These converter arrangements sometimes have a particularly high luminance that can be generated. For this purpose, the converter can be irradiated, for example, using a blue laser beam (˜450 nm) at high irradiance (for example >50 W/mm2), due to which a part of the light is emitted as yellow light. Typical diameters of the laser beam spot can be in the range from 0.1 mm up to several millimetres. In this manner, high luminances of the yellow light can be generated. Theoretically, in a converter having an efficacy of 300 lm/W for example, a specific light emission of 15,000 lm/mm2 can be achieved, which corresponds with Lambert's emission characteristic of the converters to a luminance of approximately 5000 cd/mm2.
In practice, however, these luminances are not reached. The reasons for this are, on the one hand, a temperature-related reduction of the efficacy at high irradiances and furthermore the light diffusion, due to which widening of the emitted light spot occurs in particular at small diameters of the laser light spot. This is induced in particular by the index of refraction of the converter material. The high index of refraction of the converter material is problematic, since, on the one hand, it reduces the light decoupling cone due to the high critical angle of the total reflection and, on the other hand, it additionally obstructs the coupling of the blue light and the decoupling of the yellow light due to a high Fresnel reflection.
A high Fresnel reflection can be reduced by dielectric coatings on the converter, however, it is problematic in this case to reduce the interface reflection over both a broad wavelength range and a broad angle range.
What is needed in the art is to minimize light spreading of the secondary light caused by the total internal reflection at the converter surface, in particular in order to increase the achievable luminance, and to constrict a Lambert's emission characteristic of emitted light, in particular to enable an increased coupling efficiency of the light into following illumination beam paths. What is also needed in the art is to remain compatible with existing manufacturing processes and to achieve optimum matching to the optical systems in which components are used. What are also needed in the art are a high temperature stability and thus power stability, a matching of the decoupling characteristic to the optical system, improved coupling of blue light in particular and decoupling of yellow light, a possibility for matching the emission spectrum of light.
The invention relates to an illumination device including a light source for emitting primary light and a light conversion element, wherein the light conversion element is configured to be illuminated using the primary light emitted by the light source and to emit secondary light having a different wavelength on its front side. More specifically, the invention relates to an illumination device including at least one light source, designed as a laser in particular, for emitting primary light, a light conversion element having a front side, wherein the light conversion element is configured to be illuminated using the primary light emitted by the light source and to emit secondary light having a different wavelength on its front side, and an optical element, which is attached to the front side of the light conversion element such that a first optical interface is formed between the light conversion element and the optical element, so that secondary light can be coupled from the light conversion element into the optical element at the first optical interface, and wherein the optical element includes an outer surface, which forms a second optical interface to a surrounding medium, wherein (a) the outer surface includes at least one surface area B extending obliquely in relation to the front side of the light conversion element, so that secondary light can be decoupled at the second optical interface from the optical element into the surrounding medium in a direction which has a smaller angle in relation to the normal of the front side of the light conversion element than if the surface area B were to extend in parallel to the front side of the light conversion element, and/or (b), the outer surface includes at least one surface area B′ extending obliquely in relation to the front side of the light conversion element, so that secondary light can be reflected at the second optical interface into the optical element, in particular with total reflection, in a direction toward the normal of the front side of the light conversion element.
The surface area B in particular faces away from the front side of the light conversion element and is used in particular as a refractive surface area. The surface area B′ in particular faces toward the front side of the light conversion element and is used in particular as a reflective surface area. The optical element does not need to include both surface areas B, B′. However, in specific embodiments the optical element can include both surface areas B, B′ at the same time.
The light conversion element is optionally configured to be illuminated on its front side using the primary light emitted by the light source, in particular such that the illumination device includes a remission geometry.
The optical element is optionally configured such that both the primary light and the secondary light pass through the optical element.
The outer surface of the optical element can furthermore include a surface area B″ forming the primary light, which can be, for example, part of the surface area B (or a planar section A) or part of the surface area B′ (or a planar section A′).
The illumination device, in particular the light conversion element and/or the optical element, in particular the first optical interface, can in special cases be formed such that a part of the primary light directed onto the front side of the light conversion element extends as scattered primary light in the direction of the outer surface of the optical element, in particular such that the scattered primary light can also be decoupled from the optical element into the surrounding medium at the surface area B and/or the scattered primary light can also be reflected with total reflection at the surface area B′.
The illumination device can include a beam splitter, which is dichroic in particular, and which can be arranged both in the beam path of the primary light and in the beam path of the secondary light and can be configured to deflect one of the beam paths by reflection.
The illumination device can in some embodiments include a further optical element, which is in particular arranged downstream in the beam path, and which is configured to focus and/or collimate secondary light decoupled from the optical element.
The surface area B, at which secondary light can be decoupled from the optical element, can be formed by at least one planar section A, for example, a convexly curved planar section, of the outer surface of the optical element, which optionally extends over an angle range in relation to the normal of 0° to 20°, optionally extends over an angle range in relation to the normal of 0° to 40°, optionally extends over an angle range in relation to the normal of 0° to 70°, or extends over an angle range in relation to the normal of 0° to 90°.
The surface area B, at which secondary light can be decoupled from the optical element, can be formed by at least one planar section A, for example, a convexly curved planar section, of the outer surface of the optical element, which optionally extends over a solid angle of at least 0.45π, optionally extends over a solid angle of at least 1π, optionally extends over a solid angle of at least 2π. The solid angle designates here in particular the angle range at which the section A appears from the beam exit of the secondary light from the light conversion element.
The surface area B′, at which secondary light can be reflected into the optical element with total reflection, can be formed by at least one planar section A′, for example, a convexly curved planar section, of the outer surface of the optical element, which optionally extends over an angle range in relation to the normal of 1° to 90°, optionally extends over an angle range in relation to the normal of 10° to 90°, optionally extends over an angle range in relation to the normal of 40° to 90°, or extends over an angle range in relation to the normal of 60° to 90°.
The surface area B′, at which secondary light can be reflected into the optical element with total reflection, can be formed by at least one planar section A′, for example, a convexly curved planar section, of the outer surface of the optical element, which optionally extends over a solid angle of at least 1π, optionally extends over a solid angle of at least 1.5π, optionally extends over a solid angle of at least 1.95π.
The outer surface of the optical element and/or the planar section A of the outer surface of the optical element can be at least partially, in particular completely spherically shaped, optionally over an angle range in relation to the normal of 0° to 20°, optionally over an angle range in relation to the normal of 0° to 40°, optionally over an angle range in relation to the normal of 0° to 70°, or over an angle range in relation to the normal of 0° to 90°.
The outer surface of the optical element and/or the planar section A of the outer surface of the optical element can be at least partially, in particular completely spherically shaped, optionally over a solid angle of at least 0.45π, optionally over a solid angle of at least 1π, optionally over a solid angle of at least 2π.
The outer surface of the optical element and/or the planar section A′ of the outer surface of the optical element can be at least partially parabolically shaped, optionally over an angle range in relation to the normal of 1° to 90°, optionally over an angle range in relation to the normal of 10° to 90°, optionally over an angle range in relation to the normal of 40° to 90°, or over an angle range in relation to the normal of 60° to 90°.
The outer surface of the optical element and/or the planar section A′ of the outer surface of the optical element can be at least partially parabolically shaped, optionally over a solid angle of at least 1π, optionally over a solid angle of at least 1.5π, optionally over a solid angle of at least 1.95π.
The secondary light, which can be decoupled from the optical element at the surface area B, can optionally be decoupled in a direction toward the normal of the front side of the light conversion element.
The outer surface of the optical element, in particular the planar section A or the planar section A′ of the outer surface of the optical element, can be designed to focus and/or collimate the secondary light and/or to restrict the angle range of the light emission.
The surface area B, at which secondary light can be decoupled from the optical element, optionally the planar section A, can be designed such that secondary light can be decoupled thereon, which can be coupled in the center of the first optical interface into the optical element.
The surface area B′, at which secondary light can be reflected into the optical element with total reflection, optionally the planar section A′, can be designed such that secondary light can be reflected thereon, which can be coupled in the center of the first optical interface into the optical element.
It can be provided that the optical element, in particular on its side facing toward the light conversion element, is provided at least partially, in particular completely, with a coating, in particular with a reflective dielectric or metallic coating, wherein the outer surface of the optical element, in particular only the outer surface of the optical element, is at least partially, in particular completely provided with a coating, in particular with a dielectric coating, an antireflective coating, a dichroic coating, and/or a color-shifting coating. Optionally, it can furthermore be provided that the optical element, in particular the surface area B′, optionally the planar section A′, includes a reflective coating.
The light conversion element can include one or more of the following materials: ceramic converter material, Ce:YAG, Ce:GYAG, in particular YAG with Gd at Y position, Ce:LuAG, Ce:GaLuAG.
The light conversion element can include polycrystalline material, in particular homogeneous polycrystalline material.
The light conversion element can include inorganic material, which can be formed in particular as a matrix material in which light-converting particles are embedded.
The light conversion element can include monocrystalline material, in particular can consist of monocrystalline material.
The light conversion element optionally has an index of refraction which is greater than 1.5 or is greater than 1.6 or is greater than 1.7 or is greater than 1.8.
The optical element can include one or more of the following materials: glass, in particular LaSF, N-LaSF9, LASF35, P-LASF51, SF glass, (all available i.a. by SCHOTT AG) or an equivalent glass.
The optical element optionally has an index of refraction which is greater than 1.5 or is greater than 1.6 or is greater than 1.7 or is greater than 1.8, in particular, is greater than the index of refraction of the light conversion element.
The index of refraction of the optical element is optionally at most 0.3 less than that of the light conversion element, optionally at most 0.1 less than that of the light conversion element, optionally at most 0.05 less than that of the light conversion element, and is particularly optionally greater than that of the light conversion element.
The optical element can consist of or include a glass such that in the range of 440 nm to 780 nm it has an internal transmittance of at least 90% measured on a 10-mm-thick sample, and/or in the range of 500 nm to 780 nm it has an internal transmittance of at least 97% measured on a 10-mm-thick sample.
The optical element can have a coefficient of thermal expansion CTE α+20/+300° C., which is in the range of 7 to 9.5×10−6 1/K, optionally in the range of 7 to 8.5×10−6 1/K.
The optical element can have a difference of the coefficient of thermal expansion CTE between the optical element and the light conversion element which, in the temperature range between 25° C. and 300° C., is less than 2×10−6 1/K, optionally is less than 1×10−6 1/K.
The optical element optionally has a glass transition temperature TG, which is below 800° C., optionally is below 700° C.
Since the fusing of the optical element can take place at a viscosity <1010 dPas, the temperature at which the glass has a viscosity of 1010 dPas is sometimes a further important parameter for the glass used for the optical element. This is optionally below 900° C., optionally below 850° C., and particularly optionally below 800° C.
The light conversion element and the optical element, in particular their materials and/or indices of refraction, are optionally designed such that a total reflection first takes place at the first interface from an angle which is greater than 50°, optionally is greater than 70°, optionally is greater than 80°.
The light conversion element and the optical element, in particular their materials and/or indices of refraction, are optionally designed such that no, or essentially no, total reflection occurs.
The optical element, in particular its material, index of refraction, and/or outer surface, are optionally designed such that a fraction of the secondary light can be decoupled from the optical element into the surrounding medium which is greater than 30%, optionally is greater than 60%, optionally is greater than 90%, in particular in relation to the luminous flux entering the optical element from the light conversion element.
The optical element, in particular its material, index of refraction, and/or outer surface are optionally designed such that all or essentially all secondary light can be decoupled from the optical element into the surrounding medium.
The present invention furthermore relates to a method for producing a light conversion device including providing a light conversion element having a front side, wherein the light conversion element is configured to be illuminated using primary light and to emit secondary light having a different wavelength on its front side, and the melting/fusing of raw material to form an optical element on the front side of the light conversion element having a first optical interface between the light conversion element and the optical element.
The raw material can at least essentially maintain its shape during the melting/fusing such that the molten optical element obtains an outer surface which at least essentially corresponds to that of the raw material.
During the melting/fusing, a temperature increase can take place such that the raw material reaches a viscosity which is higher than 105 dPas and lower than 1010 dPas, optionally is higher than 106 dPas and is lower than 108 dPas.
During the melting/fusing, the raw material can change its shape such that the molten optical element receives an outer surface which differs from that of the raw material.
During the melting/fusing, a temperature increase can take place such that the raw material reaches a viscosity which is lower than 106 dPas, optionally is lower than 105 dPas, optionally is lower than 104 dPas.
The outer surface of the optical element can be at least partially, in particular completely spherically shaped, optionally over a solid angle of at least ½π, optionally over a solid angle of at least π, optionally over a solid angle of at least 2π.
The outer surface of the optical element can be at least partially parabolically shaped, optionally for beams originating from the apex of the parabola in an angle range of 90° to 60° in relation to the optical axis, optionally for beams in an angle range of 90° to 30° in relation to the optical axis.
The present invention furthermore relates to a light conversion device including a light conversion element having a front side, wherein the light conversion element is configured to be illuminated using primary light and to emit secondary light having a different wavelength on its front side, and an optical element, which is attached to the front side of the light conversion element such that a first optical interface is formed between the light conversion element and the optical element, so that secondary light can be coupled from the light conversion element into the optical element at the first optical interface, and wherein the optical element includes an outer surface, which forms a second optical interface to a surrounding medium, wherein (a) the outer surface includes at least one surface area B extending obliquely to the front side of the light conversion element, so that secondary light can be decoupled at the second optical interface from the optical element into the surrounding medium in a direction which has a smaller angle in relation to the normal of the front side of the light conversion element than if the surface area B were to extend parallel to the front side of the light conversion element, and/or (b) the outer surface includes at least one surface area B′ extending obliquely to the front side of the light conversion element, so that secondary light can be reflected at the second optical interface into the optical element, in particular with total reflection, in a direction toward the normal of the front side of the light conversion element.
The surface area B, at which secondary light can be decoupled from the optical element, can be formed by at least one planar section A, for example, a convexly curved planar section, of the outer surface of the optical element, which optionally extends over an angle range in relation to the normal of 0° to 20°, optionally extends over an angle range in relation to the normal of 0° to 40°, optionally extends over an angle range in relation to the normal of 0° to 70°, or extends over an angle range in relation to the normal of 0° to 90°.
The surface area B, at which secondary light can be decoupled from the optical element, can be formed by at least one planar section A, for example, a convexly curved planar section, of the outer surface of the optical element, which optionally extends over a solid angle of at least 0.45π, optionally extends over a solid angle of at least 1π, optionally extends over a solid angle of at least 2π.
The surface area B′, at which secondary light can be reflected into the optical element with total reflection, can be formed by at least one planar section A′, for example, a convexly curved planar section, of the outer surface of the optical element, which optionally extends over an angle range in relation to the normal of 1° to 90°, optionally extends over an angle range in relation to the normal of 10° to 90°, optionally extends over an angle range in relation to the normal of 40° to 90°, or extends over an angle range in relation to the normal of 60° to 90°.
The surface area B′, at which secondary light can be reflected into the optical element with total reflection, can be formed by at least one planar section A′, for example, a convexly curved planar section, of the outer surface of the optical element, which optionally extends over a solid angle of at least 1π, optionally extends over a solid angle of at least 1.5π, optionally extends over a solid angle of at least 1.95π.
The outer surface of the optical element and/or the planar section A of the outer surface of the optical element can be at least partially, in particular completely spherically shaped, optionally over an angle range in relation to the normal of 0° to 20°, optionally over an angle range in relation to the normal of 0° to 40°, optionally over an angle range in relation to the normal of 0° to 70°, or over an angle range in relation to the normal of 0° to 90°.
The outer surface of the optical element and/or the planar section A of the outer surface of the optical element can be at least partially, in particular completely spherically shaped, optionally over a solid angle of at least 0.45π, optionally over a solid angle of at least 1π, optionally over a solid angle of at least 2π.
The outer surface of the optical element and/or the planar section A′ of the outer surface of the optical element can be at least partially parabolically shaped, optionally over an angle range in relation to the normal of 1° to 90°, optionally over an angle range in relation to the normal of 10° to 90°, optionally over an angle range in relation to the normal of 40° to 90°, or over an angle range in relation to the normal of 60° to 90°.
The outer surface of the optical element and/or the planar section A′ of the outer surface of the optical element can be at least partially parabolically shaped, optionally over a solid angle of at least 1π, optionally over a solid angle of at least 1.5π, optionally over a solid angle of at least 1.95π.
The secondary light, which can be decoupled from the optical element at the surface area B, can optionally be able to be decoupled in a direction toward the normal of the front side of the light conversion element.
The outer surface of the optical element, in particular the planar section A or the planar section A′ of the outer surface of the optical element, can be designed to focus and/or collimate the secondary light and/or to restrict the angle range of the light emission.
The surface area B, at which secondary light can be decoupled from the optical element, optionally the planar section A, can be designed such that secondary light can be decoupled thereon, which can be coupled in the center of the first optical interface into the optical element.
The surface area B′, at which secondary light can be reflected into the optical element with total reflection, optionally the planar section A′, can be designed such that secondary light can be reflected thereon, which can be coupled in the center of the first optical interface into the optical element.
It can be provided that the optical element, in particular on its side facing toward the light conversion element, is provided at least partially, in particular completely, with a coating, in particular with a reflective dielectric or metallic coating, wherein the outer surface of the optical element, in particular only the outer surface of the optical element, is at least partially, in particular completely provided with a coating, in particular with a dielectric coating, an antireflective coating, a dichroic coating, and/or a color-shifting coating. Optionally, it can furthermore be provided that the optical element, in particular the surface area B′, optionally the planar section A′, includes a reflective coating.
The light conversion element can include one or more of the following materials: ceramic converter material, Ce:YAG, Ce:GYAG, in particular YAG with Gd at Y position, Ce:LuAG, Ce:GaLuAG.
The light conversion element can include polycrystalline material, in particular homogeneous polycrystalline material.
The light conversion element can include inorganic material, which can be formed in particular as a matrix material in which light-converting particles are embedded.
The light conversion element can include monocrystalline material, in particular can consist of monocrystalline material.
The light conversion element optionally has an index of refraction which is greater than 1.5 or is greater than 1.6 or is greater than 1.7 or is greater than 1.8.
The optical element can include one or more of the following materials: glass, in particular LaSF, N-LaSF9, LASF35, P-LASF51, SF glass, or an equivalent glass.
The optical element optionally has an index of refraction which is greater than 1.5 or is greater than 1.6 or is greater than 1.7 or is greater than 1.8, in particular is greater than the index of refraction of the light conversion element.
The index of refraction of the optical element is optionally at most 0.3 less than that of the light conversion element, optionally at most 0.1 less than that of the light conversion element, optionally at most 0.05 less than that of the light conversion element, and is optionally greater than that of the light conversion element.
The optical element can consist of or include a glass such that in the range of 440 nm to 780 nm, it has an internal transmittance of at least 90% measured on a 10-mm-thick sample and/or in the range of 500 nm to 780 nm, it has an internal transmittance of at least 97% measured on a 10-mm-thick sample.
The optical element can have a coefficient of thermal expansion CTE or a measured in the range (+20/+300° C.), which is in the range of 7 to 9.5×10−6 1/K, optionally is in the range of 7 to 8.5×10−6 1/K.
The optical element can have a difference of the coefficient of thermal expansion CTE between the optical element and the light conversion element which, in the temperature range between 25° C. and 300° C., is less than 2×10−6 1/K, optionally is less than 1×10−6 1/K.
The optical element optionally has a glass transition temperature TG, which is below 800° C., optionally is below 700° C.
Since the fusing of the optical element can take place at a viscosity <1010 dPas, the temperature at which the glass has a viscosity of 1010 dPas is sometimes a further important parameter for the glass used for the optical element. This is optionally below 900° C., optionally below 850° C., and optionally below 800° C.
The light conversion element and the optical element, in particular their materials and/or indices of refraction, are optionally designed such that a total reflection first takes place at the first interface from an angle which is greater than 50°, optionally is greater than 70°, optionally is greater than 80°.
The light conversion element and the optical element, in particular their materials and/or indices of refraction, are optionally designed such that no, or essentially no, total reflection occurs.
The optical element, in particular its material, index of refraction, and/or outer surface, are optionally designed such that a fraction of the secondary light can be decoupled from the optical element into the surrounding medium which is greater than 30%, optionally is greater than 60%, optionally is greater than 90%, in particular in relation to the luminous flux entering the optical element from the light conversion element.
The optical element, in particular its material, index of refraction, and/or outer surface are optionally designed such that all or essentially all secondary light can be decoupled from the optical element into the surrounding medium.
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate at least one embodiment of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
The reflection of light at the interface between converter and another optical medium having an index of refraction is described by the Fresnel formula. The reflectance calculated therefrom for light, which exits from a converter having the index of refraction nc=1.82 at a given angle α at the interface to air, is shown in
Between perpendicular incidence (α=0°) and the critical angle of the total reflection (α=γ), the reflectance is dependent on whether the light is polarized parallel (p) or perpendicular to the plane of incidence (s). In the case that the light generated in a luminescence converter is unpolarized, i.e., contains both polarization directions in equal parts, the reflection shown by bold lines in
In
The solid angle which the escape cone covers is
Ω=2π(1−cos(γ))
The fraction of the light which is emitted into a half space (W=2p) of the converter and which then lies in the escape cone is thus
F
EC=1−cos(γ)
However, not all light in the escape cone will leave the converter, since the interface reflection given by the Fresnel formula also has to be taken into consideration. Since this can be estimated well by the interface reflection with perpendicular incidence, this fraction is approximately:
F
Decoupling=[1−cos(γ)][1−RF(0)]
The fraction complementary to FEE, which suffers total internal reflection, is given by
Values for the Fresnel reflection with perpendicular incidence RF(0°), the critical angle of the total reflection Tim, the fraction of the light in the escape cone FEE, and the estimation for the fraction of the directly exiting light FDecoupling are compiled for selected interface situations in the following table.
To prevent this, luminescence converters are typically provided with scattering centers, which result in a change of the light propagation direction and thus increase the exiting light fraction. Since this only takes place after scattering events, however, the decoupled light spot is enlarged in relation to the incident light spot. This therefore reduces the achievable luminance.
The scattering can be volume scattering, or also surface scattering. Volume scattering is induced, for example by inhomogeneities in the volume of polycrystalline ceramic converters. Surface scattering is caused by a rough or structured surface. In transparent monocrystalline converter material, this is typically the only option for limiting the lateral light propagation by scattering.
An optical element 500 is in turn applied to the front side 310 of the light conversion element 300, wherein an optical contact exists between the light conversion element 300 and the optical element 500, i.e., a first optical interface G1 is formed between the light conversion element 300 and the optical element 500. At this first optical interface G1, secondary light 350 can be coupled from the light conversion element 300 into the optical element 500.
The optical element 500 moreover includes an outer surface 510, which forms a second optical interface G2 to a surrounding medium. The outer surface 510 includes different sections A, A′ and areas B, B′.
Within a planar section A extending in a curve, a surface area B extending obliquely to the front side 310 of the light conversion element 300 is located, which faces away from the front side 310. This surface area B is characterized in that secondary light 350 can be decoupled at the second optical interface G2 from the optical element 500 into the surrounding medium in a direction which has a smaller angle in relation to the normal N of the front side 310 of the light conversion element 300 than if the surface area B were to extend in parallel to the front side 310 of the light conversion element 300. In particular, in this example the secondary light 350 is refracted at the surface area B in the direction of the normal N.
Within a further planar section A′ extending in a curve, a further surface area B′ extending obliquely to the front side 310 of the light conversion element 300 is located, which faces toward the front side 310. This surface area B′ is characterized in that secondary light 350 is reflected at the second optical interface G2 in the optical element 500 with total reflection in a direction toward the normal N of the front side 310 of the light conversion element 300. The surface area B′ can optionally include a reflective coating.
The outer surface 510 of the optical element 500 moreover includes a surface area B″ at which the primary light 250 is coupled into the optical element 500. This surface area B″ can also be formed as a beamforming area, in particular to change the beam form or beam direction of the primary beam, e.g. with regard to more suitable irradiation of the light conversion element 300.
The following
Light conversion elements 300 having applied optical element 500 were experimentally implemented, for example, by: (1.) Melting glass onto converter material, due to which lens forms result solely due to the surface tension of the molten glass; (2.) Melting of ball lenses which are partially ground on one side; (3.) Melting of prisms, in particular to prove the optical contact and determine optimum melting conditions; (4.), Melting of ball lenses onto converters with rear-side silver metallization, in particular with the result that the subsequent melting of the ball lenses does not destroy the silver metallization.
A light conversion device can be produced, for example, via a melting process which enables a direct connection of the glass to the converter material. The glass element to be fused on is placed on the converter and subjected to a temperature treatment. In principle, an additional surface conditioning is not required for both components (glass and converter material); a prior cleaning is optional.
The selection of the temperature program takes place in consideration of the physicochemical properties of the glass, in particular the viscosity-temperature profile, the interface tension, the crystallization properties, and the thermal expansion (or CTE mismatch between glass and converter material).
Highly refractive glasses, as are used for the desired arrangement, represent a special challenge to the fusing process, since they often have steep viscosity curves and tend toward crystallization (in particular toward surface crystallization). The process window available is therefore small.
To obtain an intimate bond between glass and converter material, the viscosity falls below a specific limiting viscosity (or a limiting temperature is exceeded), for example, in the order of magnitude of 1010 dPas. The bond optionally provides not only mechanical stability, but also an attachment which is “optically homogeneous” over the entire surface, i.e., optionally no local air inclusions or the like are present at the interface between glass and converter.
Furthermore, a crystallization (for example in the bulk and/or at the surface) is optionally avoided, since it can reduce the transmission of the optical element, for example, or causes undesired scattering of the exiting or entering light.
The shape or contour of the optical glass element can be influenced in different ways in order to obtain a desired shape or contour: (a) The contour can be specified via a “preform” (cold glass part before fusing) and is not changed during the fusing process (at least in the optically relevant area). The surface quality of the preform is also (at least) retained during the fusing, wherein in particular with rough surfaces an improvement of the surface quality is possible in the melting process. (b) The contour of the preform is different than that of the optical element. The final contour first arises in the course of the fusing process.
In the case (a), the preform is, for example, a glass ball flattened on one side or halved. In the case (b), the preform can be, for example, a cubical element. However, other shapes are also conceivable. The surface quality of the preform can deviate in this case from that of the optical element to be formed or can also be worse. Worse is to be understood to mean: the parameters typical for characterizing surface quality, such as roughness parameter values Ra, Rq or Sa, Sq, etc. can be higher. Which of the options is selected is dependent not only on the contour of the optical element to be achieved, but is also influenced by the selection of the glass material. The temperature guides for the two variants typically differ.
In case (a), the fusing process optionally takes place in the range which corresponds to viscosities between 1010 dPas and 107 dPa. In case (b), the fusing optionally takes place at temperatures below a viscosity of 107 dPas. In this case, the shape of the optical element forms via the surface tension of the glass. However, this is obstructed by low crystallization temperatures or high crystal growth speeds. The maximum temperature in the fusing process optionally remains below a critical temperature threshold value for this purpose, or a specific temperature threshold value is only exceeded for a short time. Beginning crystallization at the glass surface results in the occurrence of scattering centers, on the one hand, directly due to the crystallite itself and also indirectly due to a wrinkled rough surface skin forming in the cooling process due to different coefficients of expansion of crystals and glass.
Glass type: N-LaSF9, index of refraction nD 1.85; 107.6 dPas at 817° C., 1013 dPas at 700° C.; crystallization: LDB lower devitrification boundary measured using gradient rod method is approximately 900° C. corresponding to approximately 105.5 dPas. Converter underlay: silver-coated Ce/YAG. Contour preform: hemisphere, surface quality preform (measurement data white light interferometry WLI, measurement field 336*336 μm2: Sg 5 nm, Sa 4 nm).
Method steps: cleaning the preform(s); cleaning the converter(s); laying the preform(s) on the converter underlay(s); clean furnace chamber, advantageous: inner sleeve in the furnace due to cleanness and to improve the temperature homogeneity, advantageous: separate cover of the arrangement made up of lens(es) and converter(s) with ceramic vessel.
Temperature program: 3 K/min to 825° C., 15 min hold, cooling at 1 K/min to 700° C., then “free” cooling.
Contour of the fused element, see
Parameter of surface of the fused half lens: from WLI measurement (measurement field 336*336 μm2): glass surface after fusing Sq=2 nm, Sa=1 nm. Glass surface before fusing (starting state of preform, see above): Sg=5 nm, Sa=4 nm
Glass type: N-LaSF9, converter underlay: silver-coated Ce/YAG, contour preform: cube, edge length (4 mm).
Method steps: cleaning the preform(s); cleaning the converter(s); laying the preform(s) on the converter underlay(s); clean furnace chamber, advantageous: inner sleeve in the furnace due to cleanness and to improve the temperature homogeneity, advantageous: separate cover of the arrangement made up of lens(es) and converter(s) with ceramic vessel.
Contour of the molten element, see
In summary, using the present invention, for example (i) a decoupling element matched in index of refraction can be applied to a ceramic converter, so that there is an optical contact between them. Furthermore, the optical element (decoupling element) can optionally (ii) be formed so that the fraction of the emitted light which is prevented from being decoupled by total internal reflection is minimized. In particular, the disadvantage of Lambert emission can be addressed hereby. The Lambert emission characteristic of a light source is disadvantageous, since it is often not possible to couple all of the radiation emitted by the light source into a downstream illumination beam path.
Optionally, the two approaches (i) and (ii) are combined. This is because a glass pane matched in index of refraction, which is applied to the converter, would reduce, for example, the light diffusion at the interface converter-glass, but would displace the problem of total reflection to the interface glass-air. The fraction of the light suffering total internal reflection would remain the same. This applies for a glass pane of any index of refraction. For example, a BK-7 glass pane would reduce the critical angle of the total reflection at the glass-air interface, but in return a fraction of the light would already be reflected at the converter-glass interface. On the other hand, a BK-7 hemispherical lens would have an optimum geometry for the light decoupling, but here too a significant part of the light would already also be reflected at the converter-glass interface.
By using inorganic material (glass), a high temperature stability and thus power stability of the arrangement can advantageously be achieved. A matching of the decoupling characteristic to the optical system can advantageously be carried out by problem-matched decoupling elements (e.g., hemispherical lens, ¾ ball lens, nearly spherical ball lens, parabolic light guide element, free-form optical unit). Improved coupling of the blue light and decoupling of the yellow light can advantageously take place due to a coating of the optical element. Furthermore, the emission spectrum of the light can be adapted by a coating. Furthermore, the optical dispersion of the optical element can be compensated by optimized beam paths for the excitation and useful light.
Applied decoupling elements can be, for example, hemispherical lenses, spherical lenses, aspheric lenses, or so-called “parabolic concentrator”, parabolically shaped light guide rods, which function like a parabolic mirror on the basis of total internal reflection. The following is to be noted with respect to the geometry of the decoupling element.
A hemispherical lens (apex height=radius) has optimum light decoupling since the entire angle spectrum of the light exiting from the converter can be decoupled. However, this geometry places high demands on the following optical units. Since the light radiates through the interface glass-air perpendicularly, this geometry is particularly suitable for the application of a dielectric coating (for example, a broadband AR coating or a coating which modifies the light color of the exiting light. With a narrowband coating having a green reflection coating, a red shift can even be achieved by reabsorption of green light and following reemission).
A parabolic light guide rod is also capable of decoupling the entire angle spectrum and has a nearly perpendicular light exit at the glass-air interface.
A ball lens having an apex height which is greater than the apex radius (for example, ¾ lens) constricts the angle-dependent intensity distribution, which simplifies the integration of the components into optical systems. However, not all light beams can leave the lens, since some beams are incident at angles on the glass-air interface which are greater than the critical angle of the total reflection.
A lens shape with h>r, which is excellent, is the spherical lens, in which for the apex height h, the relationship
applies. Since the following applies for the focal length of a spherical surface
the beam point is located here in the object-side focus and beams close to the axis are collimated. In this case, n is the object-side index of refraction, n′ is the image-side index of refraction, r is the radius of curvature of the surface, and f′ is the image-side focal length. At apex heights h>r, it can be necessary to deviate from the spherical shape in the converter-side part of the lens. For parts of the light bundle emitted by the converter, in particular for those having high aperture, total reflection can occur, which limits the decoupling cone.
An asphere can be designed so that the exiting light is collimated not only in the vicinity of the apex, but also for beams distant from the axis.
A free-form optical unit can be designed so that the light beams which exceed the critical angle of the total reflection are collimated by a parabolic light guide structure.
Flat lenses (apex height<apex radius) are also not capable of decoupling the entire angle spectrum, but nonetheless offer an improvement over a planar converter.
In the assessment of the best solution, the entire system made up of converter material, the arrangement, and the optical system is always to be observed. It can thus be useful for a simple optical system of a yellow-emitting light source to select only a ¾ lens or a parabolic light guide rod made of glass having an index of refraction which is higher than that of the very thin converter material, which scatters little or not at all.
On the other hand, it can be useful for white light applications in which a scattering converter is required in any case to utilize the intrinsic light confinement of the converter element and to entirely permit an index of refraction jump to the decoupling element, which is then manufactured, however, from a “more good-natured” glass having lower tendency toward crystallization and is more complexly shaped for this purpose, for example, aspheric primary lens, which in combination with a complex free-form optical unit permits optimum light coupling of the primary light and decoupling of the secondary light.
The present invention optionally relates to ceramic luminescence converters irradiated using laser light in remission arrangement having index of refraction n>1.8, by way of which optionally high luminances are generated. The invention also relates to converter arrangements in transmission, non-ceramic converters, and/or an excitation using other light sources instead of lasers, for example LEDs.
The present invention is therefore useful in particular for areas of application in which high luminances are important and in which laser-excited photoluminescent light sources are possibly already used. These are, for example, digital projection, headlights, for example, automobile high beams, automobile headlights, search headlights, microscopy illumination, fibre optics, for example, endoscopy, or machine vision.
While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
Number | Date | Country | Kind |
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10 2022 123 050.3 | Sep 2022 | DE | national |