PHOSPHOR PLATE AND LIGHTING DEVICE INCLUDING THE SAME

Abstract

An embodiment of the present invention relates to a phosphor plate, which is a plate-shaped photo-conversion structure in which a phosphor is dispersed inside of a glass matrix, and has an uneven surface comprising at least one type of pattern, formed on at least one surface of the both surfaces of the plate, wherein the pattern occupies 70-95% of the area of the one surface.

Claims

1. A phosphor plate comprising: a matrix having one surface and the other surface opposite the one surface; a phosphor dispersed inside the matrix; and an uneven surface disposed on at least one of the one surface and the other surface and having one or more patterns, wherein the patterns occupy 70% to 95% of the whole surface area of either the one surface or the other surface.

2. The phosphor plate of claim 1, wherein the uneven surface comprises the pattern having a size (A) of 5.0 μm to 8.0 μm.

3. The phosphor plate of claim 2, wherein the patterns have a distance (B) of 7.0 μm to 10 μm, based on a central point of one unit pattern.

4. The phosphor plate of claim 1, wherein the uneven surface has a single layout structure including a concave pattern or a convex pattern formed on a surface of the matrix, or a mixed pattern structure in which the concave pattern and the convex pattern are mixed.

5. The phosphor plate of claim 4, wherein the pattern has a height (C) or a depth (C′) of 0.3 μm to 1.5 μm.

6. The phosphor plate of claim 5, wherein the sum of the height (C) and the depth (C′) of the pattern is less than or equal to 2 μm when the pattern formed on the uneven surface is a mixed concave/convex pattern.

7. The phosphor plate of claim 3, wherein the matrix has a plate-shaped structure comprising a glass material.

8. The phosphor plate of claim 3, wherein the phosphor has a refractive index of 1.5 to 2.5.

9. The phosphor plate of claim 3, wherein the phosphor comprises two or more phosphors selected from the group consisting of yttrium-aluminum-garnet (YAG)-based, lutetium-aluminum-garnet (LuAG)-based, nitride-based, sulfide-based, and silicate-based phosphors.

10. The phosphor plate of claim 9, wherein the phosphor has a wavelength range of 530 μm to 600 μm.

11. A lighting device comprising: a light source element; and a phosphor plate disposed below the light source element, wherein the phosphor plate comprises a matrix having one surface and another surface opposite the one surface, a phosphor dispersed inside the matrix, and an uneven surface disposed on either the one surface or the other surface and having one or more patterns, and the patterns occupy 70% to 95% of the whole surface area of the one surface or the other surface.

12. The lighting device of claim 11, wherein a light exit surface of the light source element and the surface opposite the surface on which the uneven surface is formed are disposed in the phosphor plate to be adjacent to each other.

13. The lighting device of claim 12, wherein the patterns have a height (C) or a depth (C′) of 0.3 μm to 1.5 μm.

14. The lighting device of claim 11, wherein the lighting device further comprises an adhesive layer disposed between the light source element and the phosphor plate.

15. The lighting device of claim 14, wherein the adhesive layer has a thickness of 2 μm to 5 μm.

16. The lighting device of claim 11, wherein the light source element is at least one element selected from the group consisting of a light emitting diode (LED), an organic light emitting diode (OLED), a laser diode (LD), a laser, and a vertical-cavity surface-emitting laser (VCSEL).

17. The lighting device of claim 16, wherein the light source element is a blue light source element.

18. The lighting device of claim 11, wherein at least one surface of the light source element is coated with a molding material.

19. The lighting device of claim 18, wherein the molding material has a reflectance of 99.8% or more.

Description

DESCRIPTION OF DRAWINGS

[0009] FIG. 1 is a cross-sectional view of a light diffusion unit included in a lighting device according to this exemplary embodiment.

[0010] FIG. 2 is a cross-sectional view of a light diffusion unit included in a lighting device according to this exemplary embodiment.

[0011] FIG. 3 is a cross-sectional view of a light diffusion unit included in a lighting device according to this exemplary embodiment.

[0012] FIG. 4 is a perspective view of patterns applied to simulations according to this exemplary embodiment.

[0013] FIG. 5 is a chart showing results of measuring surface roughness of a phosphor plate according to this exemplary embodiment.

BEST MODE

[0014] Hereinafter, preferred embodiments of the present invention which can be easily practiced by those of ordinary skill in the art to which the present invention belongs will be described in detail with reference to the accompanying drawings.

[0015] Phosphor plates 110, 210 and 310 according to this exemplary embodiment have an uneven surface formed on at least one surface thereof. Here, the uneven surface has one or more patterns 112, 212 and 312, and the patterns 112, 212 and 312 occupy 70% to 95% of the area of the one surface.

[0016] FIGS. 1 to 3 are cross-sectional views of light diffusion units 100, 200 and 300 included in a lighting device according to this exemplary embodiment. First, the phosphor plates 110, 210 and 310 in the light diffusion units 100, 200 and 300 will be described, and the other parts 120, 130, 220, 230, 320 and 330 will be described later.

[0017] Referring to FIGS. 1 to 3, the phosphor plates 110, 210 and 310 according to this exemplary embodiment have a plate-shaped photo-conversion structure in which a phosphor is dispersed inside a matrix. The matrix of the phosphor plates 110, 210 and 310 may be formed of a glass material. In general, a phosphor in the form of particles may be mixed with a glass frit, and the resulting mixture may be sintered to obtain a phosphor plate. A material having a transmittance of 70% to 80% and a refractive index of 1.5 to 1.7 with respect to glass having a thickness of 190 μm after sintering may be used as the glass material. When the phosphor is mixed with a glass frit and the mixture is sintered, the transmittance and refractive index of the glass material may be lowered. Thus, glass materials having a proper transmittance and refractive index may be selected and used, depending on the types of phosphors. Different compositions of the glass material may be used in consideration of the desired optical characteristics and heat processing characteristics of a phosphor plate and the types of phosphors to be mixed.

[0018] A mixture including two or more phosphors selected from the group consisting of yttrium-aluminum-garnet (YAG)-based, lutetium-aluminum-garnet (LuAG)-based, nitride-based, sulfide-based, and silicate-based phosphors may be used as the phosphor. A phosphor having a wavelength range of 530 nm to 600 nm (green to yellow) may be selected as the phosphor.

[0019] A phosphor in the form of particles or powder may be used as the phosphor. In this case, a phosphor having a particle diameter of 10 μm to 20 μm may be used. In the phosphors, a phosphor having a refractive index of 1.5 to 2.5 is preferably used. The phosphor is mixed at a content of 10% by weight to 20% by weight with respect to the glass frit. In this case, an amount of the mixed phosphor may vary depending on the transmissivity and color difference after sintering. Also, the content of the phosphor may vary depending on a change in thickness. In this case, a smaller amount of the phosphor may be added when the thickness is increased.

[0020] The phosphor plates 110, 120 and 130 may be manufactured using the following method. A mixture of the glass frit and the phosphor is put into a stainless use steel (SUS) mold, and uniaxially compressed to have a plate or disc shape. The size of the mold may vary depending on the use of the phosphor plate. For example, a disc-shaped mold may be used for a down-light product for a lighting so that the product has a diameter of 50 to 100 mm and a thickness of 200 μm to 600 μm. Also, in the case of an outdoor lighting, a hexahedral mold may be used so that the phosphor plate after sintering has a size of 1×1×0.16 to 1×1×0.2 mm (W×D×H) for a product for an automotive headlamp having a size of 15×60×0.5 mm (W×D×H).

[0021] In this case, the compression is performed at a load of 5 tons to 8 tons for 5 to 10 minutes. The compressed phosphor/glass frit mixture is put into a sintering furnace to perform a sintering process. In this case, a temperature and time required to perform a sintering process may be adjusted depending on the glass transition temperatures (T.sub.g) of the phosphor and the glass frit.

[0022] The thickness of the completely sintered phosphor plates 110, 210 and 310 may be adjusted to satisfy desired characteristics in this exemplary embodiment. Surface polishing may be further performed to adjust surface roughness. In this case, the ceramic photo-conversion member is polished to have a thickness of 200 μm to 1,000 μm a surface roughness of 0.1 μm to 0.3μm.

[0023] The phosphor plates 110, 210 and 310 thus obtained may be subjected to a conventional patterning process to form patterns 112, 212 and 312, respectively. In this exemplary embodiment, a patterned sapphire substrate (PSS) process is used during an LED process to form the patterns 112, 212 and 312.

[0024] A photoresist (PR) is applied onto surfaces of the phosphor plates 110, 210 and 310 whose surfaces are finely processed, or a dry film resist (DFR) is attached to the surfaces of the phosphor plates 110, 210 and 310. The phosphor plates 110, 210 and 310 are exposed through a patterned mask, developed, and then subjected to wet or dry etching, depending on the desired characteristics. In this case, the patterns 112, 212 and 312 of the phosphor plates 110, 210 and 310 are indicated by rectangular patterns, as shown in FIGS. 1 to 3, but the present invention is not limited thereto. For example, the patterns 112, 212 and 312 may be formed as patterns having other shapes such as dome (hemispherical), conical, pyramidal, cylindrical, and hexagonal prism shapes. Also, the patterns 112, 212 and 312 may be formed as convex or concave patterns or mixed concave/convex patterns. FIG. 1 shows a convex pattern, FIG. 2 shows a mixed concave/convex pattern, and FIG. 3 shows a concave pattern. The mixed concave/convex pattern has a structure in which a concave pattern 214 is further formed within the convex pattern 212.

[0025] The size A of the patterns 112, 212 and 312 represents a size of the underside of a pattern, that is, a size of one side when the underside is in a square shape, or a diameter when the underside is in a circular shape. The size A of the patterns 112, 212 and 312 may be in a range of 5.0 μm to 8.0 μm, and the distance B of the patterns 112, 212 and 312 may be in a range of 7.0 μm to 10 μm, based on a central point of the pattern. The size A and distance B of the patterns may be adjusted to adjust the area occupancy to within a range of 70% to 95%. When the occupancy is less than 70%, it is impossible to obtain a sufficient diffuse reflection effect due to the low occupancy of the pattern shape, resulting in poorly increased light flux when compared to conventional patterns. On the other hand, when the occupancy is greater than 95%, blue light emitted from the light source element may not easily penetrate the phosphor plate, resulting in shifted color coordinates.

[0026] The height C or depth C′ of the patterns 112, 212 and 312 may be in a range of 0.3 μm to 1.5 μm. When the patterns are mixed concave/convex patterns 212 and 214 (see FIG. 2), the sum of the height C and the depth C′ should not be greater than 2 μm. In this exemplary embodiment, a reason for forming the patterns 112, 212 and 312 on the phosphor plate 110, 210 and 310 is to prevent light radiated from light source elements 120, 220 and 320 from being back-scattered on the phosphor plate. As a result, a difference in refractive index may be minimized through various patterns. Light extraction should be performed as much as possible through diffuse reflection of light. Here, when the height C or depth C′ of the patterns 112, 212 and 312 is less than 0.3 μm, it is impossible to improve light efficiency due to low diffuse reflection, and light efficiency may be rather degraded.

[0027] The lighting device according to another aspect of this exemplary embodiment includes light diffusion units 100, 200 and 300 composed of the above-described phosphor plates 110, 210 and 310 and the light source elements 120, 220 and 320, respectively. Referring to FIGS. 1 to 3, the patterned phosphor plates 110, 210 and 310 may be stacked on the light source elements 120, 220 and 320 via adhesive layers 130, 230 and 330 including at least one adhesive, respectively.

[0028] The light source elements 120, 220 and 320 are elements that emit light. By way of one example, a solid light-emitting element may be applied. A light emitting diode (LED), an organic light emitting diode (OLED), a laser diode (LD), a laser, or a vertical-cavity surface-emitting laser (VCSEL) may be used as the solid light-emitting element. Types of elements used in the art may be used as the light source elements 120, 220 and 320. In particular, in this exemplary embodiment, elements emitting bluish light may be used.

[0029] The light source elements 120, 220 and 320 are coated with the adhesive layers 130, 230 and 330 to be attached to the phosphor plates 110, 210 and 310. The adhesive layers 130, 230 and 330 may be formed by coating with at least one adhesive. After curing, the adhesive layers 130, 230 and 330 may have a thickness of 2 μm to 5 μm. When the thickness is less than 2 μm, the light source elements 120, 220 and 320 may be peeled off due to insufficient adhesive strength, and may be deformed due to heat generated from the light source elements 120, 220 320. On the other hand, when the thickness is greater than 5 μm, the refractive indices and transmittances of the light diffusion units 100, 200 and 300 may be severely degraded, resulting in declined light efficiency. Types of adhesives may be used without particular limitation as long as they are not deformed after curing due to heat generated from the light source elements 120, 220 and 320.

[0030] Also, although not shown in FIGS. 1 to 3, the peripheries of the light source elements 120, 220 and 320 may be coated and molded with a white molding material (i.e., paint) to prevent light leakage of the light source elements 120, 220 and 320. The white molding material is preferably a perfectly reflecting material having a reflectance of 99.8% or more. As necessary, a mixture of the white molding material and spherical particles having high reflectance may be used for coating.

[0031] Hereinafter, the present invention will be described in further detail with reference to exemplary embodiments thereof. However, it should be understood that the following exemplary embodiments are provided merely to aid in understanding the present invention, and not intended to limit the scope of the present invention.

[0032] [Pattern Simulations]

[0033] The patterns were simulated for pattern shape, position, convex/concave shape, arrangement, and the like under the conditions listed in the following Table 1 to determine light efficiency characteristics.

[0034] (Color coordinates and luminous intensity distributions were not considered)

[0035] The shapes of the patterns are shown in FIG. 4.

TABLE-US-00001 TABLE 1 Efficiency Items Pattern Convex/concave Top/bottom Efficiency ratio Comparative — — — 65.32 1 Example Pattern 1 Pyramid Convex Top 72.56 1.1108 Pattern 2 (4 × 4 × 2) Bottom 64.42 0.9862 Pattern 3 Concave Top 73.11 1.1193 Pattern 4 Bottom 65.8 1.0073 Pattern 5 Hemisphere Convex Top 74.77 1.1447 Pattern 6 (Φ4 × 2) Bottom 61.64 0.9437 Pattern 7 Concave Top 71.9 1.1007 Pattern 8 Bottom 66.15 1.0127 Pattern 9 Cone 1 Convex Top 73.01 1.1177 Pattern 10 (Φ4 × 2) Bottom 65.44 1.0018 Pattern 11 Concave Top 72.18 1.1050 Pattern 12 Bottom 64.57 0.9885 Pattern 13 Cone 2 Convex Top 73.94 1.1320 Pattern 14 (Φ4 × 4) Concave Top 73.57 1.1263 Pattern 15 Sphere_Hexa Convex Top 75.58 1.1571 Pattern 16 (Φ4 × 2) Concave Top 72.39 1.1082 Pattern 17 Cone_Hexa Convex Top 73.16 1.1200 Pattern 18 (Φ4 × 2) Concave Top 72.16 1.1047

[0036] (In Table 1, “Hexa” represents a structure in which one unit of the pattern is adjacent to six other units of the pattern, that is, a honeycomb structure)

[0037] From the simulation results, it was revealed that the efficiency was improved by approximately 110% or more when pyramid-shaped, spherical and conical convex/concave patterns were applied to the top surface of the phosphor plate, compared to when there were no patterns. However, it was revealed that the efficiency was slightly improved or degraded when the patterns were applied to the bottom surface of the phosphor plate.

[0038] In the case of the certain shapes, that is, conical and pyramid shapes of the patterns in which the light efficiency is maximized, it is possible to optimize an angle of an incline plane, etc. From the simulation results, it was also revealed that the denser the distance between the patterns was, the more advantageous it was to improving the light efficiency.

EXAMPLES

[0039] Preparation of Phosphor Plate

[0040] Glass and a phosphor having the following characteristics were mixed to prepare a phosphor plate having a thickness of 160 μm.

[0041] 1) Glass material

[0042] Transmittance: 75% (transmittance of glass only based on thickness of 190 μm)

[0043] Refractive index: 1.613

[0044] 2) Phosphor

[0045] LuAG phosphor having a wavelength of 550 nm, a particle diameter of 15 μm, a content of 15% by weight, and a refractive index of 1.8

[0046] Nitride phosphor having a wavelength of 595 nm, a particle diameter of 15 μm, a content of 2% by weight, and a refractive index of 2.0

Examples 1 and 2

Patterning of Phosphor Plates

[0047] One surface of the phosphor plate thus prepared was subjected to surface polishing to make the surface flat. Thereafter, the surface of the phosphor plate was coated with a photoresist according to a patterned sapphire substrate (PSS) process, exposed to light according to a pattern, and then etched to form patterns on the surface of the phosphor plate (Table 2).

TABLE-US-00002 TABLE 2 Patterning conditions Items Pattern Pattern height Example 1 PSS pattern 0.4 μm Example 2 PSS pattern 1.0 μm

[0048] [Comparative Example]

Comparative Example

[0049] The phosphor plate thus prepared was subjected to surface polishing without performing a patterning process.

[0050] [Evaluation]

[0051] 1. Evaluation of Optical Characteristics of Integrated Types

[0052] Each of the light source elements satisfying the requirements listed in the following Table 3 was coated with a silicon adhesive resin (Dow KER-2300 having a refractive index of 1.42) to a thickness of 3μm. Thereafter, each of the patterned phosphor plates of Examples 1 and 2 and the non-patterned phosphor plate of Comparative Example was attached to the light source element, and optical characteristics were measured. The results are listed in the following Table 4.

TABLE-US-00003 TABLE 3 p-GaN GaN [Mg] 5.0E18, 2000A MQW In0.14Ga.0xN 4 pairs 25A (InGaN)/80A (GaN) n-GaN GaN (4.5 μm) [Si] 1.0E19 Size 0.98 × 0.98, 2 Wires White molding WR-3001 material Reflectance: 99.8% Peak at 442 nm, FWHM 21 nm

TABLE-US-00004 TABLE 4 Relative Items Cx Cy lm comparison Example 1 0.3247 0.3273 1905.0 94% Example 2 0.3299 0.3434 2092.4 103% Comparative 0.325 0.3358 2027.0 100% Example

[0053] 2. Evaluation of Optical Characteristics of Remote Types

[0054] Each of the light source elements satisfying the requirements listed in Table 1 was mounted on an integrating sphere to determine optical characteristics. Thereafter, each of the patterned phosphor plate of Example 1 and the non-patterned phosphor plate of Comparative Example was mounted on an integrating sphere to measure color coordinates (CIE), light flux, light efficiency, and surface roughness. The results are listed in the following Table 5 and shown in FIG. 5.

TABLE-US-00005 TABLE 5 Light Light flux CIE efficiency (Lumen) Cx Cy (Lm/Wrad) Note Example 1 638.9 0.4425 0.5042 251.2 101.5% (top view) Example 1 638.2 0.4426 0.5039 251.0 101.4% (bottom view) Comparative 641.4 0.4412 0.5040 247.5   100% Example

[0055] Referring to Table 5, it can be seen that there was a change between the light flux before patterning and the light flux after patterning. Also, it was revealed that there was no difference in light flux either when a portion of the light source element in contact with the light source element was patterned or vice versa.

[0056] (In FIG. 5, Ra represents an average value for the whole section, Rq represents an RMS value of Ra (average value), Rt represents a value obtained by adding the upper and lower maximum values, based on a central line of the whole measurement section, Rz (DIN) represents a value obtained by dividing the whole measurement section into five subsections, determining the maximum values for the respective subsections, and dividing the sum of the maximum values by 5, and a color bar on the right of the drawing represents a depth of a pattern)

[0057] The description set forth herein has been merely exemplary and illustrative of exemplary embodiments for the purpose of describing the scope of the present invention, and it will be apparent to those skilled in the art to which the present invention belongs that various modifications and changes can be made without departing from the scope of the present invention. Thus, it should be understood that the exemplary embodiments set forth herein are merely exemplary embodiments for the purpose of illustration only, and not intended to limit the scope of the invention. Accordingly, it should be understood that the scope of the present invention is defined by the appended claims, and that the scope of the present invention defined by the appended claims and their equivalents is intended to cover the scope of the present invention.