Patent Application
20160079490
The invention relates to a light emitting device. In particular, the invention relates to an improved light emitting device comprising a wavelength converter.
The development of new and more energy efficient illumination devices is one of the important technical challenges which society faces. Common technologies which are more energy efficient than traditional lighting solutions are often based on Light Emitting Diodes (LEDs). High intensity light sources are interesting for many applications including spot lighting and digital light projection. For these purposes it is possible to use wavelength converters which convert light of a shorter wavelength, to light of a longer wavelength in a highly transparent luminescent material. Light of a longer wavelength can then be then extracted from just one or several instead of all surfaces, which increases the intensity of the light emitted, whereas the etendue of the light source can remain small.
However, in such applications it is important to effectively couple the light from a light source into the wavelength converter which often comprises transparent phosphor for providing wavelength conversion. Furthermore, it is desirable to maintain the generated light within the luminescent layer to avoid light loss from the points where LEDs are optically coupled to the luminescent layer. U.S. Pat. No. 7,982,229 describes a conversion structure comprising phosphor which receives light from blue LEDs, converts the light into longer-wavelength light and guides it to an exit surface, where the resulting brightness can be high. Furthermore it is suggested that there is no optical contact between the light source and the transparent luminescent material. Using an optical contact between the light source and the wavelength converter may improve coupling of light emitted by LEDs into the layer. However even though an optical contact may improve coupling of light from light emitted by the LEDs, an optical contact may also lead to loss of light from a wavelength converter through the optical contact to a surrounding medium.
With regards to the above-mentioned desired properties of a light emitting device, it is a general object of the present invention to enable improved performance of a light emitting device through an improved light emitting device arrangement comprising a wavelength converter.
According to a first aspect of the invention, these and other objectives are achieved through a light emitting device comprising a substrate, a light source arranged on the substrate and having a light exit surface, a wavelength converter configured to convert light from a first wavelength to a second wavelength, the wavelength converter having a light exit surface and a light entrance surface, and an optical coupling element, arranged between and in contact with the light exit surface of the light source and the light entrance surface of the wavelength converter, and configured to couple light from the light source to the wavelength converter, wherein at least a major portion of the surface of the wavelength converter other than the light exit surface and the light entrance surface, has a surface roughness, RA, less than 100 nm.
The present invention is based on the realization that by altering the surface characteristics of a wavelength converter, a larger portion of the light produced by the light source may be emitted in a desired direction from the wavelength converter. In particular, a low surface roughness of the wavelength converter increases the total internal reflection (TIR) within the wavelength converter which further improves the performance of light emitting device by reducing losses caused by light escaping the wavelength converter at unwanted surfaces. In principle, the overall total internal reflection of the light converter is increased with an increasing portion of the surface exhibiting the aforementioned surface roughness. Accordingly, an advantageous effect is achieved even if only a portion of the light converter exhibits said surface roughness, even though it may be desirable to provide a light converter where as large portion as possible of the surface has a surface roughness, RA, below 100 nm.
By light emitting device it should be understood that the purpose of the device is to provide lighting, and that the light source, which is commonly a LED, also can comprise of a different light generator such as e.g. lasers, flash lamps. Xenon lamps or even an X-ray source, is the main component providing this function, whereas the optical coupling element may be understood to guide the light from the light source into the wavelength converter. The wavelength converter is configured to convert light from a first wavelength to a second wavelength and to guide converted and unconverted light to the light exit surface. It should be noted that this conversion may also be a first plurality of wavelengths (i.e. a first spectrum) into a second plurality of wavelengths (i.e. a second spectrum). Furthermore, the wavelength converter is typically provided in the form of a luminescent structure comprising phosphor.
Surface roughness, RA, is a common measure for defining surface characteristics. RA is measured as the arithmetic average of absolute values, hence a plurality of measurements of the height of different points on a surface are performed and the average of the absolute measured values produces a measured surface roughness, RA. A surface roughness, RA, of less than 100 nm may allow a larger portion of the light reaching an interface between the wavelength converter and a surrounding medium (e.g. air) to be reflected back into the wavelength converter, since a low surface roughness increases the likelihood of total internal reflection (TIR). It is possible, through mechanical and/or chemical polishing, to obtain a surface roughness, RA, less than 100 nm. The surface roughness may also be defined by a certain norm, such as for example the “P3” surface quality rating according to ISO 10110, which is commonly used for high quality polished optical (glass) surfaces such as lenses, prisms etc.
A major portion of the wavelength converter other than the light exit and light entrance surface has a selected surface roughness, which may then advantageously increase the TIR within the wavelength converter and may allow more light to be reflected back into the wavelength converter at an interface with a surrounding medium. Moreover light which has not been converted, before being reflected at an interface with a surrounding medium, may be converted before being emitted through the light exit surface.
Surface characteristics of the light exit and light entrance surfaces of the wavelength converter such as surface roughness, RA, may advantageously be controlled to increase the transmittance through these surfaces.
Light reflected at an interface with a surrounding medium may then be transmitted from the light exit surface, in a desired direction, instead of escaping from the wavelength converter via an unwanted surface, i.e. a surface different from the light exit surface, thereby increasing the amount of light emitted from the light exit surface of the wavelength converter.
According to one embodiment of the invention, at least the aforementioned major portion of the wavelength converter may further comprise a coating having a surface roughness, RA, less than 10 nm and a refractive index substantially similar to the refractive index of said wavelength converter. Through the use of a coating, it may be possible to lower the surface roughness even further. For example, a diffuse reflection of less than 1 percent has been measured when a surface roughness less than 10 nm is present on the wavelength converter. Hence such a low surface roughness will even further enhance the portion of light which is subject to TIR within the wavelength converter by reducing the portion of light which is diffusively reflected. It is also desirable to provide a coating having a refractive index which is substantially similar to the refractive index of the wavelength converter so that there is no refraction at the interface between the coating and the converter.
According to another embodiment of the invention, the coating may comprise silicon oxynitride. Silicon oxynitride may advantageously be used as coating due to the ability to tune the refractive index of silicon oxynitride so that it is substantially similar to that of the wavelength converter. Furthermore, it is possible to polish silicon oxynitride through mechanical and/or chemical polishing. Through the earlier mentioned mechanical and chemical polishing it may be possible to achieve a surface roughness, RA, less than 10 nm using a coating comprising silicon oxynitride which is mechanically and chemically polished. Such a low surface roughness may even further enhance the TIR within the wavelength converter. Furthermore, in the manufacturing process, it may be much easier/cost effective to polish the silicon oxynitride coating to a very high surface quality, rather than polishing the material of the wavelength converter itself, which may have a very high hardness, or may not be suitable for certain polishing techniques like e.g. chemical polishing.
In one embodiment of the invention, the wavelength converter may have a refractive index higher than the refractive index of the optical coupling element. According to a further embodiment, the refractive index of the optical coupling element may be in the range of 1.0-1.7, preferably 1.1-1.6 and most preferably 1.2-1.5 and the refractive index of the wavelength converter may be in the range of 1.5-2.0, preferably 1.7-1.9 and most preferably 1.8. Any combination of the refractive index of the optical coupling element and the refractive index of the wavelength converter is possible, but preferably the refractive index of the wavelength converter is higher than the refractive index of the optical coupling element.
Together with the surface roughness, the refractive index of the optical coupling element will determine the portion of light being reflected at the interface between the optical coupling element and the wavelength converter for a given wavelength. A refractive index of the optical coupling element is in embodiments selected in relation to the refractive index of the wavelength converter such that a larger amount of light impinging on the interface between the wavelength converter and the optical coupling element is reflected, thereby enabling a larger portion of the converted light to be emitted in a desired direction. Concurrently, configuring the refractive index of the optical coupling element in relation to the wavelength converter may enable a larger portion of light to be transmitted through the interface from the optical coupling element and into the wavelength converter, which thereby may increase the amount of light converted in the wavelength converter, whereby a larger amount of light may be emitted in a desired direction by the light emitting device. The ranges and values given for the refractive indexes above advantageously have been demonstrated to provide a large degree of TIR at the interface between the wavelength converter and the optical coupling element.
In one embodiment of the invention the light emitting device may further comprise at least one reflecting element, arranged facing, and at a distance from, at least a surface of the wavelength converter opposite the light exit surface of the wavelength converter. A reflecting element may advantageously be used to reflect light, which has passed through an interface between the wavelength converter and a surrounding medium at an unwanted surface, back into the wavelength converter. The reflecting element may be a mirror or a diffuse reflector. Commercial alternatives for a mirror may be MIRO-Silver (Alanod), while another alternative for a diffuse reflective element may be a micro cellular polyethylene terephthalate (MCPET).
According to one embodiment of the invention, the at least one reflecting element may advantageously be arranged at a distance from said wavelength converter larger than said first and second wavelength, i.e. no optical contact. Separating the reflecting element from the wavelength converter will ensure that a portion of the light which has passed through the interface between the wavelength converter and a surrounding medium is reflected back into the wavelength converter. Furthermore, arranging the reflector at a distance larger than the first or second wavelength has the effect of optically decoupling the reflector from the wavelength converter.
In one embodiment of the invention the wavelength converter may advantageously be shaped such that the light exit surface is larger than a surface opposite to the light exit surface. Accordingly, the wavelength converter may advantageously be shaped as a wedge or frustum.
Increasing the size of the light exit surface in relation to the opposite surface allows a larger amount of light reflected in the surface opposite the light exit surface to be emitted through the light exit surface. Furthermore, by shaping the wavelength converter as a wedge or frustum, a larger light exit surface can be chosen such that the other surfaces will direct the light towards the light exit surface.
In another embodiment of the invention, the light emitting device may further comprise a heat conducting element, arranged adjacent to at least one surface of the wavelength converter other than the light exit surface and at a distance from the wavelength converter such that heat conduction from the wavelength converter to the heat conducting element is allowed.
A heat conducting element which is thermally coupled to the wavelength converter provides the possibility for the wavelength converter to transfer heat to the heat conducting element. By transporting heat away from the wavelength converter, the wavelength converter may continue to convert light efficiently for a longer period of time or indefinitely without failure or without reduction in performance due to high temperatures.
In one embodiment of the invention the heat conducting element may be thermally coupled to the substrate. Thermally coupling the heat conducting element to the substrate allows heat transfer from the wavelength converter through the heat conducting element to the substrate.
In another embodiment of the invention, the reflecting elements may be arranged on the heat conducting element facing the wavelength converter. By arranging the reflecting elements on the heat conducting element facing the wavelength converter, the reflecting elements may be optically decoupled from the wavelength converter while the heat conducting element is thermally coupled to the wavelength converter.
According to one embodiment of the invention, the reflecting elements may be arranged at a plurality of surfaces of the wavelength converter, or arranged at all surfaces except the light entrance surface and the light exit surface of the wavelength converter. Arranging reflecting elements at a plurality of surfaces or all surfaces except the light entrance surface and the light exit surface, may further improve the portion of light which is reflected back into the wavelength converter, whereby the reflecting elements may further increase the amount of light being emitted from the wavelength converter in a desired direction.
In one embodiment of the invention, the heat conducting element may be thermally coupled to external cooling means. External cooling means may for example comprise a heat sink, radiator, peltier cooling plate etc. Thereby, more efficient cooling may be achieved.
According to an embodiment of the invention the light exit surface and the light entrance surface extend in an angle different from zero to one another. In other words, the light exit surface and the light entrance surface extend in planes that are not parallel to each other. In this way a light emitting device is obtained with which more light is coupled into the wavelength converter and with which an optimally large amount of light is guided towards the respective light exit surface by means of total internal reflection (TIR). This in turn lowers the amount of light lost by exiting the wavelength converter, acting also as a light guide, through other surfaces than the light exit surface and thus further increases the intensity and thus the light exit surface and the light entrance surface extend in an angle different from zero to one another brightness of the light emitted through the light exit surface. In an embodiment the light exit surface and the light entrance surface are perpendicular to one another.
Further features of, and advantages with, the present invention will become apparent when studying the appended claims and the following description. The skilled person realize that different features of the present invention may be combined to create embodiments other than those described in the following, without departing from the scope of the present invention.
This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing an embodiment of the invention.
As illustrated in the figures, the sizes of layers, elements and regions are exaggerated for illustrative purposes and, thus, are provided to illustrate the general structures of embodiments of the present invention. Like reference numerals refer to like elements throughout, such that e.g. a light emitting device according to the invention is generally denoted 1, whereas different specific embodiments thereof are denoted by adding 01, 02, 03 and so forth to the general reference numeral. With regard to
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the invention to the skilled person.
The following description will start with general considerations regarding applications, suitable light sources and suitable materials for various elements and features of a light emitting device according to the invention. Thereupon a number of features and elements which may be added to any one of the embodiments of a light emitting device according to the invention will be described with reference to
A light emitting device according to the invention may be used in applications including but not being limited to a lamp, a light module, a luminaire, a spot light, a flash light, a projector, a digital projection device, automotive lighting such as e.g. a headlight or a taillight of a motor vehicle, arena lighting, theater lighting and architectural lighting.
The light emitting device according to the invention comprises a light source, which is adapted for, in operation, emitting light with a first spectral distribution. This light is subsequently coupled into a light guide which furthermore is arranged to convert the wavelength of the incoming light to another wavelength range. The light guide is also called a wavelength converter or waveguide throughout the description of the invention. The light guide converts the light of the first spectral distribution to another spectral distribution and guides the light to an exit surface. The light source may in principle be any type of point light source, but is in an embodiment a solid state light source such as a Light Emitting Diode (LED), a Laser Diode or Organic Light Emitting Diode (OLED), a plurality of LEDs or Laser Diodes or OLEDs or an array of LEDs or Laser Diodes or OLEDs. The LED may in principle be an LED of any color, and is in an embodiment a blue light source producing light source light in the blue color-range which is defined as a wavelength range of between 380 nm and 495 nm. In another embodiment, the light source is an UV or violet light source, i.e. emitting in a wavelength range of below 420 nm. In case of a plurality or an array of LEDs or Laser Diodes or OLEDs, the LEDs or Laser Diodes or OLEDs may in principle be LEDs or Laser Diodes or OLEDs of two or more different colors, such as, but not limited to, UV, blue, green, yellow or red.
In yet another embodiment, the light source is a red light source, i.e. emitting in a wavelength range of e.g. between 600 nm and 800 nm. Such a red light source may be e.g. a red light source of any of the above mentioned types directly emitting red light or provided with a phosphor suitable for converting the light source light to red light. This embodiment is particularly advantageous in combination with a light guide adapted for converting the light source light to IR light, i.e. light with a wavelength of more than about 800 nm and in a suitable embodiment with a peak intensity in the range from 810 to 850 nm. In an embodiment such a light guide preferably comprises an IR emitting phosphor. A light emitting device with these characteristics is especially advantageous for use in night vision systems, but may also be used in any of the applications mentioned above.
In embodiments light guides generally are rod shaped or bar shaped light guides comprising a height H, a width W, and a length L extending in mutually perpendicular directions and is in an embodiment transparent and luminescent.
The height H is preferably <10 mm, more preferably <5, most preferably <2 mm. The width W is preferably <10 mm, more preferably <5, most preferably <2 mm. The length L is preferably larger than the width W and the height H, more preferably at least 2 times the width W or 2 times the height H, most preferably at least 3 times the width W or 3 times the height H. The aspect ratio of the Height H:Width W is typically 1:1 (for e.g. general light source applications) or 1:2, 1:3 or 1:4 (for e.g. special light source applications such as headlamps) or 4:3, 16:10, 16:9 or 256:135 (for e.g. display applications).
In embodiments light guides generally comprise a light input surface and a light exit surface. The light exit surface can have any shape, but is in an embodiment shaped as a square, rectangle, round, oval, triangle, pentagon, or hexagon.
The generally rod shaped or bar shaped light guide can have any cross sectional shape, but in embodiments has a cross section the shape of a square, rectangle, round, oval, triangle, pentagon, or hexagon. In embodiments light guides generally are cuboid, but may be provided with a different shape than a cuboid, with the light input surface having somewhat the shape of a trapezoid. By doing so, the light flux may be even enhanced, which may be advantageous for some applications.
Suitable materials for embodiments of light guides are sapphire, polycrystalline alumina and/or undoped transparent garnets such as YAG, LuAG having a refractive index of n=1.7. An additional advantage of this material (above e.g. glass) is that it has a good thermal conductivity, thus diminishing local heating. Other suitable materials include, but are not limited to, glass, quartz and transparent polymers. In another embodiment the light guide material is lead glass. Lead glass is a variety of glass in which lead replaces the calcium content of a typical potash glass and in this way the refractive index can be increased. Ordinary glass has a refractive index of n=1.5, while the addition of lead produces a refractive index ranging up to 1.7.
The light guide or waveguide comprises a luminescent material for converting the light to another spectral distribution. Suitable luminescent materials as used in embodiments of the invention include inorganic phosphors, such as doped YAG, LuAG, organic phosphors, organic fluorescent dyes and quantum dots which are highly suitable for the purposes of embodiments of the present invention.
Quantum dots are small crystals of semiconducting material generally having a width or diameter of only a few nanometers. When excited by incident light, a quantum dot emits light of a color determined by the size and material of the crystal. Light of a particular color can therefore be produced by adapting the size of the dots. Most known quantum dots with emission in the visible range are based on cadmium selenide (CdSe) with a shell such as cadmium sulfide (CdS) and zinc sulfide (ZnS). Cadmium free quantum dots such as indium phosphide (InP), and copper indium sulfide (CuInS2) and/or silver indium sulfide (AgInS2) can also be used. Quantum dots show very narrow emission band and thus they show saturated colors. Furthermore the emission color can easily be tuned by adapting the size of the quantum dots. Any type of quantum dot known in the art may be used in embodiments of the present invention. However, it may be preferred for reasons of environmental safety and concern to use cadmium-free quantum dots or at least quantum dots having very low cadmium content.
Organic fluorescent dyes can be used as well. The molecular structure can be designed such that the spectral peak position can be tuned. Examples of suitable organic fluorescent dyes materials are organic luminescent materials based on perylene derivatives, for example compounds sold under the name Lumogen® by BASF. Examples of suitable compounds include, but are not limited to, Lumogen® Red F305, Lumogen® Orange F240, Lumogen® Yellow F083, and Lumogen® F170.
Obviously, the luminescent material may also be an inorganic phosphor. Examples of inorganic phosphor materials include, but are not limited to, cerium (Ce) doped YAG (Y3Al5O12) or LuAG (Lu3Al5O12). Ce doped YAG emits yellowish light, whereas Ce doped LuAG emits yellow-greenish light. Examples of other inorganic phosphors materials which emit red light may include, but are not limited to ECAS and BSSN; ECAS being Ca1-xAlSiN3:Eux wherein 0<x≦1, preferably 0<x≦0.2; and BSSN being Ba2-x-zMxSi5-yAlyN8-yOy:Euz wherein M represents Sr or Ca, 0≦x≦1, 0≦y≦4, and 0.0005≦z≦0.05, and preferably 0≦x≦0.2.
According to an embodiment of the present invention, the luminescent material is essentially made of material selected from the group comprising (M<I>1-x-yM<II>xM<III>y)3(M<IV>1-zM<V>z)5O12- where M<I> is selected from the group comprising Y, Lu or mixtures thereof, M<II> is selected from the group comprising Gd, La, Yb or mixtures thereof, M<III> is selected from the group comprising Tb, Pr, Ce, Er, Nd, Eu or mixtures thereof, M<IV> is Al, M<V> is selected from the group comprising Ga, Sc or mixtures thereof, and 0≦x≦1, 0≦y≦0.1, 0≦z≦1, (M<I>1-x-yM<II>x,M<III>y)2O3- where M<I> is selected from the group comprising Y, Lu or mixtures thereof, M<II> is selected from the group comprising Gd, La, Yb or mixtures thereof, M<III> is selected from the group comprising Tb, Pr, Ce, Er, Nd, Eu, Bi, Sb or mixtures thereof, and 0≦x≦1, 0≦y≦0.1, (M<I>1-x-yM<II>xM<III>y)S1-zSez- where M<I> is selected from the group comprising Ca, Sr, Mg, Ba or mixtures thereof, M<II> is selected from the group comprising Ce, Eu, Mn, Tb, Sm, Pr, Sb, Sn or mixtures thereof, M<III> is selected from the group comprising K, Na, Li, Rb, Zn or mixtures thereof, and 0≦x≦0.01, 0≦y≦0.05, 0≦z≦1, (M<I>1-x-yM<II>xM<III>y)O- where M<I> is selected from the group comprising Ca, Sr, Mg, Ba or mixtures thereof, M<II> is selected from the group comprising Ce, Eu, Mn, Tb, Sm, Pr or mixtures thereof, M<III> is selected from the group comprising K, Na, Li, Rb, Zn or mixtures thereof, and 0≦x≦0.1, 0≦y≦0.1, (M<I>2-xM<II>xM<III>2)O7- where M<I> is selected from the group comprising La, Y, Gd, Lu, Ba, Sr or mixtures thereof, M<II> is selected from the group comprising Eu, Tb, Pr, Ce, Nd, Sm, Tm or mixtures thereof, M<III> is selected from the group comprising Hf, Zr, Ti, Ta, Nb or mixtures thereof, and 0<=x<=1, (M<I>1-xM<II>xM<III>1-yM<IV>y)O3- where M<I> is selected from the group comprising Ba, Sr, Ca, La, Y, Gd, Lu or mixtures thereof, M<II> is selected from the group comprising Eu, Tb, Pr, Ce, Nd, Sm, Tm or mixtures thereof, M<III> is selected from the group comprising Hf; Zr, Ti, Ta, Nb or mixtures thereof, and M<IV> is selected from the group comprising Al, Ga, Sc, Si or mixtures thereof, and 0≦x≦0.1, 0≦y≦0.1, or mixtures thereof.
Particularly suitable luminescent materials, however, are Ce doped Yttrium aluminum garnet (YAG, Y3Al5O12) and Lutetium-Aluminum-Garnet (LuAG). Each of the two or more luminescent light guides comprises a different central emission wavelength within a blue color-range or within a green color-range or within a red color-range. The blue color-range is defined between 380 nanometer and 495 nanometer, the green color-range is defined between 495 nanometer and 590 nanometer, and the red color-range is defined between 590 nanometer and 800 nanometer.
Turning now to
The light guide 400 shown in
This embodiment is advantageous in that the surface area of the light exit surface is smaller than the surface area required to build a light source consisting of direct light emitting LEDs. Thereby, a gain in etendue can be realized.
Alternatives for generating white light with a blue or UV light source include but are not limited to:
LEDs emitting blue light, which light is converted to green/blue light in the first conversion part 61100, which in turn is converted to white light by the second conversion part being provided as a red phosphor, and
LEDs emitting blue light, which light is converted to green light in the first conversion part 61100, which in turn is mixed with red and blue light to generate a white LED source, wherein the mixing is achieved by means of a second conversion part in the form of a red phosphor in front of which a diffusor is arranged.
A selection of phosphors according to embodiments of the invention is given in table 1 below along with the maximum wavelength which they are capable of emitting.
The light guide 401 shown in
The plurality of LEDs 2100, 2200, 2300 are used to pump the first conversion part 61100, which is in the embodiment shown made of a transparent material, to produce light 1700 having a third spectral distribution, such as green or blue light. The phosphor wheel 16, which is rotating in a rotation direction 161 about an axis of rotation 162, is then used for converting the light 1700 to light 1400 having a second spectral distribution, such as red and/or green light. It is noted that in principle any combination of colors of the light 1700 and the light 1400 is feasible.
As shown in
Alternatively, the phosphor wheel 16 may be used in the reflective mode, i.e. such that light is emitted from the same surface as the surface through which it enters the phosphor wheel 16, cf.
The phosphor wheel 16 may comprise one phosphor throughout. Alternatively, the phosphor wheel 16 may also comprise segments without any phosphor such that also part of the light 1700 may be transmitted without being converted. In this way sequentially other colors can be generated. In another alternative, the phosphor wheel 16 may also comprise multiple phosphor segments, e.g. segments of phosphors emitting yellow, green and red light, respectively, such as to create a multi-colored light output. In yet another alternative, the light emitting device 1001 may be adapted for generating white light by employing a pixelated phosphor-reflector pattern on the phosphor wheel 16.
The coupling element 700 is in an embodiment an optical element suitable for collimating the light 1700 incident on the phosphor wheel 16, but may also be a coupling medium or a coupling structure such as e.g. the coupling medium or the coupling structure 700 described above.
The light emitting device 1001 may furthermore comprise additional lenses and/or collimators. For example, additional optics may be positioned such as to collimate the light emitted by the light sources 2100, 2200, 2300 and/or the light 1400 emitted by the light emitting device 1001.
The optical element 801 is made of a material having a high refractive index, in an embodiment a refractive index which is equal to or higher than that of the light guide 402, and comprises a quadrangular cross section and two tapered sides 803 and 804. The tapered sides 803 and 804 are inclined outwards from the light exit surface 4200 of the light guide 402 such that the light exit facet 805 of the optical element 801 has a larger surface area than both the light input facet 806 and the light exit surface 4200 of the light guide 402. The optical element 801 may alternatively have more than two, particularly four, tapered sides. In an alternative, the optical element 801 has a circular cross section and one circumferential tapered side.
With such an arrangement light will be reflected at the inclined sides 803 and 804 and has a large chance to escape if it hits the light exit facet 805, as the light exit facet 805 is large compared to the light input facet 806. The shape of the sides 803 and 804 may also be curved and chosen such that all light escapes through the light exit facet 805.
The light concentrating element 802 is made of a material, such as a compound material, having high refractive index, in an embodiment a refractive index being equal to or higher than that of the light guide 403, and comprises a quadrangular cross section and two curved sides 803 and 804. The curved sides 803 and 804 are curved outwards from the light exit surface 4200 of the light guide 403 such that the light exit surface 805 of the light concentrating element 802 has a larger surface area than the light exit surface 4200 of the light guide 403. The light concentrating element 802 may alternatively have more than two, particularly four, tapered sides. In an alternative, the light concentrating element 802 has a circular cross section and one circumferential tapered side. In an embodiment, the curved sides 803, 804 are parabolic.
If, in an alternative, the refractive index of the light concentrating element 802 with curved sides 803 and 804 is chosen to be lower than that of the light guide 403 (but higher than that of air), still an appreciable amount of light can be extracted. This allows for a light concentrating element 802 which is easy and cheap to manufacture compared to one made of a material with a high refractive index. For instance, if the light guide 403 has a refractive index of n=1.8 and the light concentrating element 802 has a refractive index of n=1.5 (glass), a gain of a factor of 2 in light output may be achieved. For a light concentrating element 802 with a refractive index of n=1.8, the gain would be about 10% more.
Actually, not all light will be extracted since there will be Fresnel reflections at the interface between the optical element 801 or the light concentrating element 802 and the external medium, generally being air. These Fresnel reflections may be reduced by using an appropriate anti-reflection coating, i.e. a quarter-lambda dielectric stack or moth-eye structure. In case the light output as function of position over the light exit facet 805 is inhomogeneous, the coverage with anti-reflection coating might be varied, e.g. by varying the thickness of the coating.
By using any one of the above structures shown in
One of the interesting features of a compound parabolic light concentrating element (CPC) 802 as shown in
For instance, for a digital projector there will be requirements to the size (height and width) of the beam, as well as for the divergence. The corresponding etendue will be conserved in a CPC. In this case it will be beneficial to use a CPC with rectangular light input and exit facets 806 and 805 having the desired height/width ratio of the display panel used.
For a spot light application, the requirements are less severe. The light exit facet 805 of the CPC may be circular, but may also have another shape (e.g. rectangular) to illuminate a particularly shaped area or a desired pattern to project such pattern on screens, walls, buildings, infrastructures etc.
Although CPCs offer a lot of flexibility in design, their length can be rather large. In general, it is possible to design shorter optical elements with the same performance. To this end, the surface shape and/or the exit surface may be adapted, e.g. to have a more curved exit surface such as to concentrate the light.
One additional advantage is that the CPC can be used to overcome possible aspect ratio mismatches when the size of the light guide 403 is restrained by the dimensions of the LED and the size of the light exit facet 805 is determined by the subsequent optical components.
Furthermore, it is possible to place a mirror (not shown) partially covering the light exit facet 805 of the CPC, e.g. using a mirror which has a ‘hole’ near or in its center. In this way the exit plane of the CPC is narrowed down, part of the light is being reflected back into the CPC and the light guide, and thus the exit etendue of the light would be reduced. This would, naturally, decrease the amount of light that is extracted from the CPC and light guide. However, if this mirror has a high reflectivity, like e.g. Alanod 4200AG, the light can be effectively injected back into the CPC and light guide, where it may be recycled by TIR. This will not change the angular distribution of the light, but it will alter the position at which the light will hit the CPC exit plane after recycling thus increasing the luminous flux. In this way, part of the light, that normally would be sacrificed in order to reduce the system etendue, can be re-gained and used to increase for example the homogeneity.
This is of major importance if the system is used in a digital projection application. By choosing the mirror in the different ways, the same set of CPC and light guide can be used to address systems using different panel sizes and aspect ratio's, without having to sacrifice a large amount of light. In this way, one single system can be used for various digital projection applications.
In many applications, such as spot lighting and automotive lighting, it is desired to obtain a light distribution having a particular shape such as to comply with particular requirements given for such applications. For example, for automotive lighting there are requirements specified in the law that are related to the illumination profile of automotive head lights. Also, obtaining a light distribution having a particular shape may be desirable for decorative or aesthetic reasons.
With reference to
As may be seen, a part 4501 of the light guide 404 extending throughout the length of the light guide 404, particularly adjacent to the surface 4500 and opposite to the light input surface 4100, has been removed such as to provide the light guide 404 with a shape corresponding to the desired shape of the light distribution at the light exit surface 4200, the shape extending throughout the entire length of the light guide 404 from the light exit surface 4200 to the opposite surface 4600.
As may be seen, a part 4501 of the light guide 405 extending over a part of the length of the light guide 405, particularly adjacent to the surface 4500 and opposite to the light input surface 4100, has been removed such as to provide the light guide 405 with a shape corresponding to the desired shape of the light distribution at the light exit surface 4200, the shape extending over a part of the length of the light guide 405 adjacent the light exit surface 4200.
Another part or more than one part of the light guide may be removed such as to provide for other shapes of the light exit surface. Any feasible shape of the light exit surface may be obtained in this way. Also, the light guide may be divided partly or fully into several parts having different shapes, such that more complex shapes may be obtained. The part or parts removed from the light guide may be removed by means of e.g. sawing, cutting or the like followed by polishing of the surface that is exposed after the removal of the part or parts. In another alternative a central part of the light guide may be removed, e.g. by drilling, such as to provide a hole in the light exit surface.
In an alternative embodiment shown in
At the light exit surface 4200 an optical element 99 is provided. The optical element 99 comprises a filter 991 for filtering the light 1700 emitted from the light guide 407 such as to provide filtered light 1701, at least one further light source 993, 994 and an optical component 992 adapted for combining the filtered light 1701 and the light from the at least one further light source 993, 994 such as to provide a common light output 1400. The filter 991 may be an absorption filter or a reflective filter, which may be fixed or switchable. A switchable filter may e.g. be obtained by providing a reflective dichroic mirror, which may be low-pass, band-pass or high-pass according to the desired light output, and a switchable mirror and placing the switchable mirror upstream of the dichroic mirror seen in the light propagation direction. Furthermore, it is also feasible to combine two or more filters and/or mirrors to select a desired light output. The filter 991 shown in
The optical component 992 as shown may be a cross dichroic prism also known as an X-cube or it may in an alternative be a suitable set of individual dichroic filters.
In the embodiment shown two further light sources 993 and 994 are provided, the further light source 993 being a blue light source and the further light source 994 being a green light source. Other colors and/or a higher number of further light sources may be feasible too. A further option is to use the light filtered out by the filter 991 as a further light source.
The common light output 1400 is thus a combination of light 1701 emitted by the light guide 407 and filtered by the filter 991 and light emitted by the respective two further light sources 993 and 994. The common light output 1400 may advantageously be white light.
The solution shown in
In a further advantageous embodiment cooling of the light guide 407 is provided—e.g. by providing one or more heat sink elements as will be described further below in relation to
The light guide 408 is adapted for converting at least a part of the light with the first spectral distribution to light with a third spectral distribution different from the first spectral distribution and for guiding the light with the second spectral distribution without converting it. In this way the light 1700 emitted by the light guide 408 through the light exit surface 4200 comprises a combination of at least the light with the second and third spectral distribution, respectively, and possibly also of the light with the first spectral distribution, as part of this light may remain unconverted.
By way of a non-limiting example, the first spectral distribution may be in the wavelength range below 400 nm, the second spectral distribution may be in the red wavelength range, i.e. 500 to 800 nm and the third spectral distribution may be in the wavelength range 400 to 500 nm. By way of another non-limiting example, the first spectral distribution may be in the green wavelength range, i.e. 400 to 500 nm, the second spectral distribution may be in the red wavelength range, i.e. 500 to 800 nm and the third spectral distribution may be in the wavelength range 440 to 600 nm. By way of yet another non-limiting example the first light sources 2100, 2200, 2300 may be emitting in the wavelength range 440 to 480 nm, the light guide 408 may convert the light emitted by the first light sources to light with a wavelength in the range 480 to 600 nm and the second light source 2400 may be emitting in the wavelength range 600 to 800 nm. It is noted that in principle all feasible combinations of first, second and third spectral distributions may be used. Thereby a simple and efficient way of producing white light is obtained.
It is noted that the second light source 2400 may be provided at any one of the surfaces of the light guide 408 different from the light input surface 4100. Also, more than one second light source may be provided.
As shown on
Furthermore, second light sources may alternatively or additionally be arranged at more than one of the surfaces of the light guide 408 different from the light input surface 4100, e.g. at two different surfaces. In such an embodiment it is furthermore feasible to provide second light sources emitting light with different spectral distributions such that second light sources arranged at different surfaces emit light having different spectral distributions.
Irrespective of the embodiment the respective heat sink element 7000A, 7000B comprises fins 7100, 7200, 7300 for improved heat dissipation, the fins, however, being optional elements.
Irrespective of the embodiment the respective heat sink element 7000A, 7000B is a heat sink element adapted to be conformable to the surface shape of the light guide, and is thus adapted for providing a conformal thermal contact over the whole contact area with the light guide. Thereby improved cooling of the light guide is obtained and the existing tolerance limits on the positioning of the heat sink element become less critical.
Furthermore, the heat sink element 7000A comprises a common carrier 7050 to which the heat sink parts 7001, 7002, 7003 and 7004 are attached individually by means of attachment elements 7010, 7020, 7030 and 7040, respectively. Alternatively each heat sink part may be assigned its own carrier. It is noted that these elements are optional.
The heat sink element 7000B further comprises a thermally conductive layer 7070 arranged between the bottom element 7060 and the remainder of the heat sink element 7000B for improved flexibility and conformability of the heat sink element 7000B. The thermally conductive layer 7070 may e.g. be a thermally conductive fluid or paste. The thermally conductive layer 7070 is in an embodiment highly reflective and/or comprises a highly reflective coating.
The heat sink element 7000B further comprises a fluid reservoir 7080 arranged inside the heat sink element 7000B for generating a fluid flow for improved heat dissipation. In an alternative, the fluid reservoir 7080 may also be arranged externally on the heat sink element 7000B, e.g. extending along a part of or the whole external periphery of the heat sink element 7000B. The fluid flow may be enhanced by means of a pump.
It is noted that the conductive layer 7070 and the fluid reservoir 7080 are optional elements.
Irrespective of the embodiment, the heat sink element 7000A, 7000B may be made of a material selected from copper, aluminum, silver, gold, silicon carbide, aluminum nitride, boron nitride, aluminum silicon carbide, beryllium oxide, silicon-silicon carbide, aluminum silicon carbide, copper tungsten alloys, copper molybdenum carbides, carbon, diamond, graphite, and combinations of two or more thereof.
Furthermore, a heat sink element combining features of the embodiments described above is feasible. Also, it is feasible to arrange a heat sink element according to any of the above embodiments at more than one surface of the light guide 409A or 409B.
Finally it is noted that the provision of a heat sink element as described above is especially advantageous in embodiments of a light emitting device according to the invention employing a light source emitting in the red wavelength range and/or being adapted for emitting light in the infrared wavelength range, e.g. by comprising an IR emitting phosphor.
Irrespective of the embodiment the polarizing element 9001 may be any one of a reflective linear polarizer and a reflective circular polarizer. Wire grid polarizers, reflective polarizers based on stack of polymer layers comprising birefringent layers are examples of reflective linear polarizers. Circular polarizers can be obtained using polymers in the so-called cholesteric liquid crystal phase to make so-called cholesteric polarizers transmitting only light of one polarization and of a specific spectral distribution. Alternatively or in addition to the reflective polarizers, polarizing beam splitters can also be employed. Furthermore scattering polarizers can also be used. In another embodiment, polarization by reflection may be used, e.g. by means of a polarizing element in the form of a wedge made of a material like glass, in which light is incident close to the Brewster angle. In yet another embodiment, the polarizing element 9001 may be a so-called polarized backlight such as described in WO 2007/036877 A2. In yet another embodiment, the polarizing element 9001 may be a polarizing structure.
Furthermore, the light guide 4010A comprises a ¼ lambda plate 9002 arranged at one of the surfaces extending between the light exit surface 4200 and the surface 4600, in the embodiment shown the surface 4500. In the embodiment shown the ¼ lambda plate 9002 covers the surface 4500 partially. Alternatively, the ¼ lambda plate may cover the surface 4500 completely or it may comprise two or more separate segments. Alternatively or in addition thereto, further ¼ lambda plates may be arranged at one or more other of the surfaces extending between the light exit surface 4200 and the surface 4600. In yet another embodiment the ¼ lambda plate 9002 may be arranged between the light guide and the reflective element 7400 such that a gap is provided between the ¼ lambda plate and the light guide. A ¼ lambda plate 9002 may be used for converting light with a first polarization into light with a second polarization, particularly for converting circularly polarized light into linearly polarized light. It is noted, however, that irrespective of the embodiment the ¼ lambda plate 9002 is an optional element, and that it thus may also be omitted.
In further alternative embodiments the polarizing element 9001 may be provided as a part of an optical element arranged at the light exit surface 4200 of the light guide. In one particular embodiment the polarizing element 9001 is then arranged such as to be located opposite to the light exit surface 4200 in the mounted position of the optical element. By way of example such an optical element may for instance be an optical element 801, a compound parabolic light concentrating element (CPC) 802 or an optical element 99 as described above and shown in
A portion of the light of a first wavelength entering the wavelength converter 106 will be converted into light of a second wavelength, and after the conversion process it will be emitted in a random direction. The portion of converted light and a portion which may not have been converted, will impinge on the interface between the wavelength converter 106 and a surrounding medium. Due to low surface roughness, RA less than 100 nm, of the surfaces other than the light exit surface 110 and the light entrance surface 114, light impinging at the interfaces will have a large likelihood of TIR and thereby a large likelihood of being reflected back into the wavelength converter 106. Hence, light will be directed towards the light exit surface 110.
A major portion of the wavelength converter 106 other than the light entrance surface and the light exit surface 110 can be covered in a coating which has a surface roughness, RA, less than 10 nm and a refractive index which is substantially similar to the wavelength converters refractive index. This will further improve the likelihood of TIR at the interface between the wavelength converter 106 and a surrounding medium. The coating may comprise silicon oxynitride, since silicon oxynitride is able to be polished both mechanically and chemically. The wavelength converter 106 will in embodiments have a refractive index which is higher than the refractive index of the optical coupling element 112. The refractive index of the optical coupling element 112 is in the range of 1.0-1.7, preferably 1.1-1.6 and most preferably 1.2-1.5 and the refractive index of the wavelength converter 106 is in the range of 1.5-2.0, preferably 1.7-1.9 and most preferably 1.8. As an example, the wavelength converter may preferably comprise Ce doped Yttrium Aluminum Garnet (YAG, Y3Al5O12) and Lutetium-Aluminum-Garnet (LuAG) having a refractive index around 1.8. Then the refractive index of the optical coupling element is most preferably in the range 1.2-1.5.
Furthermore the light exit surface 110 is arranged in a plane which is essentially perpendicular to the plane of the light exit surface of the light source 104 and the light entrance surface 114 is arranged in a plane which is parallel to the plane of the light exit surface of the light source 104. Thereby, it is possible to collect light from a large number of LEDs and concentrating the light output to a surface which may be significantly smaller than the combined light input surface, thus providing a wavelength converter which can provide high intensity light. In embodiments the light exit surface 110 is arranged in a plane having another angle than perpendicular, but not parallel, with the plane of the light exit surface of the light source 104.
Referring now to
In
In
Even though the invention has been described with reference to specific exemplifying embodiments thereof, many different alterations, modifications and the like will become apparent for those skilled in the art. For example the light source could be a laser, OLED, or another material or device producing light or radiation, as e.g. X-ray scintillators may be used to convert X-ray into visible light. The reflecting elements may be introduced as described with or without the heat conducting element.
Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2014/059774 | 3/14/2014 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 61806462 | Mar 2013 | US |
