LED apparatus employing tunable color filtering using multiple neodymium and fluorine compounds
10648642 ยท 2020-05-12
Assignee
Inventors
- Kevin Jeffrey Benner (Solon, OH)
- Gary Robert Allen (Chesterland, OH)
- Dengke Cai (Mentor, OH, US)
- Thomas Clynne (East Cleveland, OH)
- Jianmin He (Orange, OH, US)
Cpc classification
F21K9/232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L33/507
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L33/44
ELECTRICITY
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G02B5/223
PHYSICS
F21Y2113/13
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/66
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V3/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C08L2666/72
CHEMISTRY; METALLURGY
F21K9/233
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S8/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L2924/00014
ELECTRICITY
H01J9/20
ELECTRICITY
H01J61/40
ELECTRICITY
F21V9/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
C08L2666/72
CHEMISTRY; METALLURGY
H01L2224/8592
ELECTRICITY
F21K9/23
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V7/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/60
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01K1/32
ELECTRICITY
F21V3/0625
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V7/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
H01L25/075
ELECTRICITY
F21K9/64
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V3/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The specification and drawings present a new apparatus such as a lighting apparatus, the apparatus comprising at least one LED (or OLED) module configured to generate a visible light such as white light, and at least one component such as an optical component comprising multiple (two or more) compounds, each containing neodymium (Nd) and at least one compound including fluorine (F) for imparting a desired color filtering effect to provide a desired light spectrum, where a color of the desired light spectrum in a color space is determined by relative amounts of the two or more compounds in the at least one component.
Claims
1. An apparatus comprising: at least one light emitting diode (LED) module, configured to generate a visible light; a phosphor; and at least one component comprising two or more compounds, wherein at least one of the two or more compounds comprises Nd.sub.2O.sub.3, and wherein at least another one of the two or more compounds comprises a neodymium oxyfluoride having formula of Nd.sub.1O.sub.xF.sub.y where 2x+y=3 or a neodymium hydroxide fluoride having formula Nd(OH).sub.aF.sub.b where a+b=3, the at least one component being configured to provide a desired light spectrum by filtering the generated visible light using the two or more compounds, wherein a color of the desired light spectrum in a color space is determined by relative amounts of the two or more compounds in the at least one component, and wherein the at least one component-comprises more amount of the neodymium oxyfluoride having formula of Nd.sub.1O.sub.xF.sub.y where 2x+y=3 or the neodymium hydroxide fluoride having formula Nd(OH).sub.aF.sub.b where a+b=3 than the amount Nd.sub.2O.sub.3.
2. The apparatus of claim 1, wherein the color of the desired light spectrum in the color space is varied within a predefined area in the color space defined at least by absorption vectors of the two or more compounds.
3. The apparatus of claim 2, wherein the predefined area in the color space is limited to about twelve MacAdam ellipses.
4. The apparatus of claim 1, wherein the at least another one of the two or more compounds comprises NdF.sub.3.
5. The apparatus of claim 1, wherein the at least one component is an encapsulating layer deposited on a top of the at least one LED module.
6. The apparatus of claim 5, wherein the encapsulating layer is a low temperature glass, a polymer, a polymer precursor, a polycarbonate, a thermoplastic or thermoset polymer or resin, a silicone, or a silicone epoxy resin.
7. The apparatus of claim 1, wherein the at least one component is an encapsulating layer deposited on a further encapsulating layer comprising a phosphor, the further encapsulating layer being deposited on a top of the at least one LED module.
8. The apparatus of claim 1, wherein the at least one component is an optical component comprising a transparent, translucent or reflective substrate with a coating on a surface of the substrate, the coating comprising the two or more compounds to provide the desired light spectrum by filtering the generated visible light.
9. The apparatus of claim 8, wherein a thickness of the coating is in a range from about 50 nm to about 1000 microns.
10. The apparatus of claim 1, wherein the at least one component or the phosphor further comprises an additive having a higher refractive index than the two or more compounds, and wherein the additive is selected from metal oxides and non-metal oxides including at least one of TiO.sub.2, SiO.sub.2 and Al.sub.2O.sub.3.
11. The apparatus of claim 8, wherein the substrate is a diffuser being selected from the group consisting of a bulb, a lens, and a dome enclosing the at least one LED module.
12. The apparatus of claim 1, wherein the apparatus comprises an integrated circuit containing a plurality of LED modules with a corresponding plurality of components.
13. The apparatus of claim 1, wherein the at least another one of the two or more compounds comprises the neodymium oxyfluoride.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These and other features and aspects of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings, in which like characters represent like parts throughout the drawings, wherein:
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DETAILED DESCRIPTION
(13) A new apparatus such as a lighting apparatus is presented herein, the apparatus comprising at least one LED (or OLED) module configured to generate a visible light such as white light, and at least one component such as an optical component comprising multiple (two or more) compounds, each comprising neodymium (Nd) and at least one compound comprising fluorine (F) for imparting a desired color filtering effect to provide a desired light spectrum, where a color of the desired light spectrum in a color space is determined by relative amounts of the two or more compounds in the at least one component.
(14) For example, according to one embodiment of the invention, the at least one component (optical component) may be a polymer base material (such as silicone, polycarbonate and the like) comprising two compounds: a first compound may be neodymium oxide (Nd.sub.2O.sub.3) and a second compound may be neodymium fluoride (NdF.sub.3), as this case is described in detail herein. The neodymium compounds absorb yellow light in the 560-600 nm range, which alters the color point of the LED system. The addition of a single compound can move the color point along a line in the CIE 1931 color space (with chromaticity coordinates CCX and CCY). By using two or more compounds the color point can be moved anywhere within an area of the CIE color space (hereinafter color space). This allows for greater customization of the color of the LED system for a particular application as demonstrated in
(15) In other words, the neodymium compounds (such as Nd.sub.2O.sub.3 and NdF.sub.3 in the above example) can be added in various amounts to change the composition of the optical component for controlling the color point of the resulting light. The different absorption spectra of the two (or more) components result in movement of the color point of the LED system in different directions (i.e., in both CCX and CCY directions) when each component is added. Then color point movement vectors of the multiple compounds comprising Nd and F, described herein, can bound an area within the CIE color space, inside of which any color point can be achieved with the same LED, by varying the relative amounts of the two or more compounds, as described herein.
(16) According to another embodiment, a scattering element, such as titania (TiO2), alumina (Al.sub.2O.sub.3), silica (SiO.sub.2) or the like, may be added to the polymer base to increase the diffusivity of the multiple Nd and F compounds in the optical component. Variation of three variables (e.g., weight loading of TiO2, NdF3, and Nd.sub.2O.sub.3 for the above example) may allow creation of a wide variety of specialized optical components for achieving a desired light spectrum and distribution.
(17) Moreover, according to one embodiment of the invention, at least one compound (or more than one) may comprise elements of neodymium (Nd) and fluorine (F), and optionally comprising one or more other elements. Typically such compound comprises Nd.sup.3+ ions and F.sup. ions. For the purpose of this invention, a NdF compound should be broadly construed to include compounds comprising neodymium and fluoride and optionally other elements.
(18) According to a further embodiment, the component may include a composite/encapsulating layer on a surface of the LED (OLED) chip so that multiple compounds comprising Nd and F disclosed herein, can be blended (dispersed) in that encapsulating layer, e.g., along with a phosphor, to achieve favorable visible absorption profiles. The composite/encapsulating layer may be formed using a low temperature glass, a polymer (such as polycarbonate), a polymer precursor, a silicone (polymer) or silicone epoxy resin or precursor, and the like.
(19) According to another embodiment, the optical component may be a transparent, translucent reflective or transflective (partially reflective and transmitting) substrate, and a coating on a surface of the substrate comprising multiple Nd and F components described herein, can apply a color filtering effect to the visible light, generated by the LED module, while it is passing through the optical component, e.g., to filter the visible light in the yellow light wavelength range, for example, for wavelengths from about 560 nm to about 600 nm to provide a desired light spectrum.
(20) Furthermore, the transparent or translucent substrate of the optical component may be a diffuser, such as a bulb, a lens and an envelope enclosing at least one LED chip. Moreover, the substrate may be a reflective substrate, and the LED chip can be arranged outside of the substrate. The multi-compound coating (comprising Nd and F multiple compounds described herein) may be disposed on a surface of the substrate, and the thickness of the coating should be sufficient to achieve the color filtering effect. The thickness may typically be within a range from 50 nm to 1000 microns, with a preferred thickness being between 100 nm to 500 microns.
(21) The resultant devices can exhibit improvement of light parameters using filtering with Nd and NdF compounds/materials having intrinsic absorption in the visible region between about 530 nm and 600 nm to enhance CSI (color saturation index), CRI (color rendering index), R9 (color rendering value) revealness (lighting preference index, LPI) and the like. R9 is defined as one of 6 saturated test colors not used in calculating CRI. The revealness is a parameter of the emitted light based on a version of the LPI, which is described in co-pending, commonly owned International application PCT/US2014/054868, filed Sep. 9, 2014 (published as WO2015/035425 on Mar. 12, 2015), and hereby incorporated by reference in pertinent part.
(22) In one embodiment, at least one of the multiple compounds described herein may including Nd.sup.3+ ions and F.sup. ions and may be a NdF compound or a NdXF compound. As used herein, the NdF compound should be broadly construed to include compounds including neodymium and fluoride and optionally other elements. Such compounds comprising neodymium and fluoride may comprise neodymium fluoride, or neodymium oxyfluoride (e.g., NdO.sub.xF.sub.y where 2x+y=3, such as Nd.sub.4O.sub.3F.sub.6) or neodymium fluoride comprising adventitious water and/or oxygen, or a neodymium hydroxide fluoride (e.g., Nd(OH).sub.aF.sub.b where a+b=3), or numerous other compounds comprising neodymium and fluoride which will be become readily apparent from the following description.
(23) In some embodiments, one of the multiple compounds may be NdF3 or NdFO. For the NdXF compound, X is at least one element selected from the group consisting of: elements that form compounds with neodymium, such as, oxygen, nitrogen, sulfur and chlorine, or at least one metallic element that form compounds with fluorine, such as Na, K, Al, Mg, Li, Ca, Sr, Ba, and Y, or combinations of such elements, said metallic elements being different from neodymium. Particular examples of NdXF compounds may include: neodymium oxyfluoride (NdOF) compounds; NdXF compounds in which X may be Mg and Ca or may be Mg, Ca and O; as well as other compounds containing NdF, including perovskite structures doped with neodymium. Certain NdXF compounds may advantageously enable broader absorption at wavelengths of about 580 nm.
(24) As stated above, one component/optical component may be a polymer base material (such as silicone, polycarbonate and the like) comprising, for example, two compounds Nd.sub.2O.sub.3 and NdF.sub.3.
(25) In use, one may encapsulate an LED chip/die with an encapsulant (e.g., silicone, epoxy, acrylic, or the like); the encapsulant may comprise Nd.sub.2O.sub.3 and NdF.sub.3 material or in general Nd and F based compounds as described herein, such that, e.g., Nd.sub.2O.sub.3 and NdF.sub.3 in silicone can be deposited directly on the LED chip or on the array of LED chips (e.g., chip-on-board array, COB array) as further detailed herein.
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(27) As it is clear from the diagram in
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(32) In a further embodiment, the multiple Nd and F compounds of corresponding relative amounts may be blended into an encapsulating material along with one or more luminescent materials, such as phosphors. For example, the Nd and F multiple compounds of corresponding relative amounts may be blended with a yellow-green phosphor and/or a red phosphor. For example, the multiple Nd and F compounds may be blended with a Ce-doped YAG phosphor and/or a conventional red nitride phosphor, such as a Eu.sup.2+-doped CaAlSiN red phosphor. In another example, the Nd and F multiple compounds can be blended with YAG:Ce phosphor and a red nitride phosphor in silicone, encapsulating a blue/ultraviolet-emitting LED.
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(34) According to one embodiment shown in
(35) To form a polymer composite layer that includes the multiple Nd and F compounds of corresponding relative amounts, described herein, on a surface of an LED chip, the particles may be dispersed in a polymer or polymer precursor, particularly a silicone, polycarbonate, silicone epoxy resin, or precursors therefor. Such materials are well known for LED packaging. The dispersion mixture can be coated on the chip by any suitable process, for example using injection molding (or casting and extruding the optical component or similar techniques), and particles having a larger density or particle size, or a larger density and larger particle size, preferentially settle in the region proximate the LED chip, forming a layer having a graded composition. Settling may occur during the coating or curing of the polymer or precursor, and may be facilitated by a centrifuging process, as known in the art. It is further noted that the parameters of dispersion of the phosphor and the Nd and F multiple compounds, e.g., including particle density and size and process parameters, can be chosen to provide the phosphor material being closer to the LED chip 65 than the Nd and F multiple compounds, in order to provide an appropriate filtering by the Nd and F multiple compounds of the light generated by the phosphor component.
(36) In an alternative exemplary embodiment shown in
(37) In a further exemplary embodiment shown in
(38) In yet a further exemplary embodiment, as shown in
(39) Below are several non-limiting examples of a LED-based lighting apparatus using the coating containing the Nd and F multiple compounds, described herein causing a desired color filter effect.
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(44) The coating materials described herein, including a compound containing Nd3+ ions and F ions, may have little optical scattering (diffusion) effect; or, alternatively, may cause considerable optical scattering on light passing therethrough. To increase a scattering angle, the coating may include discrete particles of an organic or inorganic material. Alternatively, the organic or inorganic material can be solely made up of discrete particles of the Nd and F multiple compounds described herein, and/or made up of a mixture of discrete particles of the Nd and F multiple compounds and particles formed of at least one other different material.
(45) In one embodiment, a suitable particle size for the organic or inorganic material can be from about 1 nm to about 10 microns. For the LED lamp 70 shown in
(46) Although not intended to be limiting, the Nd and F multiple compound coating may be applied by, for example, spray coating, roller coating, meniscus or dip coating, stamping, screening, dispensing, rolling, brushing, bonding, electrostatic coating or any other method that can provide a coating of even thickness. The following will describe three non-limiting examples of how to provide the Nd and F multiple compound coating on the substrate.
(47) In one embodiment, as shown in
(48) In another embodiment, as shown in
(49) In one embodiment, as shown in
(50) In another embodiment of the invention, both the spray coating method and the electrostatic coating method may use materials without organic solvent or organic compound, which can extend the service life of the LED light apparatus and avoid the discoloration typically caused by sulfonation.
(51) In a further embodiment, to promote refraction of the light to achieve a white reflective appearance, the coating further may include an additive having a higher refractive index relative to the multiple Nd and F compounds. The additive can be selected from at least one of metal oxides or non-metal oxides, such as TiO.sub.2, SiO.sub.2 and Al.sub.2O.sub.3.
(52) Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one having ordinary skill in the art to which this disclosure belongs. The terms first, second, and the like, as used herein, do not denote any order, quantity, or importance, but rather are employed to distinguish one element from another. Also, the terms a and an do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. The use of including, comprising or having and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as additional items. The terms connected and coupled are not restricted to physical or mechanical connections or couplings, and can include electrical and optical connections or couplings, whether direct or indirect.
(53) Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. The various features described, as well as other known equivalents for each feature, can be mixed and matched by one of ordinary skill in this art, to construct additional systems and techniques in accordance with principles of this disclosure.
(54) In describing alternate embodiments of the apparatus claimed, specific terminology is employed for the sake of clarity. The invention, however, is not intended to be limited to the specific terminology so selected. Thus, it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions.
(55) It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments are within the scope of the following claims.
(56) It is noted that various non-limiting embodiments described and claimed herein may be used separately, combined or selectively combined for specific applications.
(57) Further, some of the various features of the above non-limiting embodiments may be used to advantage, without the corresponding use of other described features. The foregoing description should therefore be considered as merely illustrative of the principles, teachings and exemplary embodiments of this invention, and not in limitation thereof.