Solid-state lamps utilizing photoluminescence wavelength conversion components
10557594 ยท 2020-02-11
Assignee
Inventors
Cpc classification
F21V7/048
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/233
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V29/83
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G02B6/00
PHYSICS
F21V29/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V3/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/64
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21K9/64
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V3/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V7/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V29/506
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V29/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V29/83
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/233
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G02B6/00
PHYSICS
Abstract
Disclosed are improved photoluminescence wavelength conversion components and lamps that incorporate such components. The photoluminescence wavelength conversion component comprises a hollow cylindrical tube having a given bore of diameter and an axial length. The relative dimensions and shape of the component can affect the radial emission pattern of the component and are configured to give a required emission pattern (typically omnidirectional). The photoluminescence material can be homogeneously distributed throughout the volume of the component during manufacture of the component. An extrusion method can be used to form the improved photoluminescence wavelength conversion component. Injection molding or casting can also be used to form the component. Another possible approach is to manufacture the component is by forming a flexible sheet material to include the phosphor and/or quantum dots, and then rolling the sheet material into the desired shape and dimensions for the component. The improved wavelength conversion components and lamps that incorporate these components provide for improved emission characteristic, while allowing for relatively cost-effective manufacturing costs. A further advantage of components is that their light emission resembles a filament of a conventional incandescent light bulb.
Claims
1. A photoluminescence wavelength conversion component comprising: a cylindrical light transmissive component comprising a plurality of latitudinally extending phosphor regions which are equally circumferentially spaced and have at least one photoluminescence material; the cylindrical light transmissive component having first and second ends and a substantially constant cross section, wherein the first end is for receiving light; and a light reflective surface provided over at least a part of the second end, wherein the light transmissive component comprises a solid component with a light transmissive core.
2. The photoluminescence wavelength conversion component of claim 1, wherein the plurality of latitudinally extending phosphor regions project into the light transmissive core.
3. The photoluminescence wavelength conversion component of claim 1, wherein the plurality of latitudinally extending phosphor regions have a semi-circular cross section.
4. The photoluminescence wavelength conversion component of any one of claims 1 to 3, wherein the cylindrical light transmissive component is elongate.
5. The photoluminescence wavelength conversion component of claim 4, wherein the ratio of the length of the cylindrical light transmissive component to width is at least two to one.
6. The photoluminescence wavelength conversion component of claim 4, wherein the ratio of the length of the cylindrical light transmissive component to width is at least four to one.
7. The photoluminescence wavelength conversion component of claim 1, wherein the cylindrical light transmissive component has a circular cross section.
8. The photoluminescence wavelength conversion component of claim 1, wherein the cylindrical light transmissive component has an elliptical, triangular, square, pentagonal, or hexagonal cross section.
9. The photoluminescence wavelength conversion component of claim 1, wherein the cylindrical light transmissive component is manufactured using a process selected from the group consisting of: extrusion; injection molding; and casting.
10. The photoluminescence wavelength conversion component of claim 1, wherein light emission of the component resembles that of a filament of an incandescent light bulb.
11. The photoluminescence wavelength conversion component of claim 1, wherein the at least one photoluminescence material is incorporated in and homogeneously distributed throughout a volume of the plurality of latitudinally extending phosphor regions.
12. The photoluminescence wavelength conversion component of claim 1, wherein the cylindrical light transmissive component is located with at least one solid-state light source operable to generate excitation light and configured to emit excitation light into the first end of the component.
13. The photoluminescence wavelength conversion component of claim 12, wherein the cylindrical light transmissive component and the at least one solid-state light source are incorporated into a lamp.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In order that the present invention is better understood, LED lamps and photoluminescence components in accordance with embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
DETAILED DESCRIPTION
(17) Lamps (light bulbs) are available in a number of forms, and are often standardly referenced by a combination of letters and numbers. The letter designation of a lamp typically refers to the particular shape of type of that lamp, such as General Service (A, mushroom), High Wattage General Service (PSpear shaped), Decorative (Bcandle, CAtwisted candle, BAbent-tip candle, Fflame, Pfancy round, Gglobe), Reflector (R), Parabolic aluminized reflector (PAR) and Multifaceted reflector (MR). The number designation refers to the size of a lamp, often by indicating the diameter of a lamp in units of eighths of an inch. Thus, an A-19 type lamp refers to a general service lamp (bulb) whose shape is referred to by the letter A and has a maximum diameter two and three eights of an inch. As of the time of filing of this patent document, the most commonly used household light bulb is the lamp having the A-19 envelope, which in the United States is commonly sold with an E26 screw base.
(18) There are various standardization and regulatory bodies that provide exact specifications to define criteria under which a manufacturer is entitled to label a lighting product using these standard reference designations. With regard to the physical dimensions of the lamp, ANSI provides the specifications (ANSI C78.20-2003) that outline the required sizing and shape by which compliance will entitle the manufacture to permissibly label the lamp as an A-19 type lamp. Besides the physical dimensions of the lamp, there may also be additional specifications and standards that refer to performance and functionality of the lamp. For example in the United States the US Environmental Protection Agency (EPA) in conjunction with the US Department of Energy (DOE) promulgates performance specifications under which a lamp may be designated as an ENERGY STAR compliant product, e.g. identifying the power usage requirements, minimum light output requirements, luminous intensity distribution requirements, luminous efficacy requirements and life expectancy.
(19) The problem is that the disparate requirements of the different specifications and standards create design constraints that are often in tension with one another. For example, the A-19 lamp is associated with very specific physical sizing and dimension requirements, which is needed to make sure A-19 type lamps sold in the marketplace will fit into common household lighting fixtures. However, for an LED-based replacement lamp to be qualified as an A-19 replacement by ENERGY STAR, it must demonstrate certain performance-related criteria that are difficult to achieve with a solid-state lighting product when limited to the form factor and size of the A-19 light lamp.
(20) For example, with regard to the luminous intensity distribution criteria in the ENERGY STAR specifications, for an LED-based replacement lamp to be qualified as an A-19 replacement by ENERGY STAR it must demonstrate an even (+/20%) luminous emitted intensity over 270 with a minimum of 5% of the total light emission above 270. The issue is that LED replacement lamps need electronic drive circuitry and an adequate heat sink area; in order to fit these components into an A-19 form factor, the bottom portion of the lamp (envelope) is replaced by a thermally conductive housing that acts as a heat sink and houses the driver circuitry needed to convert AC power to low voltage DC power used by the LEDs. A problem created by the housing of an LED lamp is that it blocks light emission in directions towards the base as is required to be ENERGY STAR compliant. As a result many LED lamps lose the lower light emitting area of traditional bulbs and become directional light sources, emitting most of the light out of the top dome (180 pattern) and virtually no light downward since it is blocked by the heat sink (body), which frustrates the ability of the lamp to comply with the luminous intensity distribution criteria in the ENERGY STAR specification.
(21) Currently LED replacement lamps are considered too expensive for the general consumer market. Typically an A-19, 60 W replacement LED lamp costs many times the cost of an incandescent bulb or compact fluorescent lamp. The high cost is due to the complex and expensive construction and components used in these lamps.
(22) An LED-based lamp 100 in accordance with embodiments of the invention is now described with reference to
(23) The lamp 100 comprises a generally conical shaped thermally conductive body 110. The outer surface of the body 110 generally resembles a frustum of a cone; that is, a cone whose apex (vertex) is truncated by a plane that is parallel to the base (i.e. substantially frustoconical). The body 110 is made of a material with a high thermal conductivity (typically 150 Wm.sup.1K.sup.1, preferably 200 Wm.sup.1K.sup.1) such as for example aluminum (250 Wm.sup.1K.sup.1), an alloy of aluminum, a magnesium alloy, a metal loaded plastics material such as a polymer, for example an epoxy. Conveniently the body 110 can be die cast when it comprises a metal alloy or molded, by for example injection molding, when it comprises a metal loaded polymer.
(24) A plurality of latitudinal radially extending heat radiating fins (veins) 120 is circumferentially spaced around the outer curved surface of the body 110. Since the lamp is intended to replace a conventional incandescent A-19 light bulb the dimensions of the lamp are selected to ensure that the device will fit a conventional lighting fixture. The body 110 further comprises a conical shaped pedestal portion 130 extending from the base of the body 110. The body 110 can further comprise a coaxial cylindrical cavity (not shown) that extends into the body from the truncated apex the body for housing rectifier or other driver circuitry for operating the lamp.
(25) The lamp 100 further comprises an E26 connector cap (Edison screw lamp base) 140 enabling the lamp to be directly connected to a mains power supply using a standard electrical lighting screw socket. It will be appreciated that depending on the intended application other connector caps can be used such as, for example, a double contact bayonet connector (i.e. B22d or BC) as is commonly used in the United Kingdom, Ireland, Australia, New Zealand and various parts of the British Commonwealth or an E27 screw base (Edison screw lamp base) as used in Europe. The connector cap 140 is mounted to the truncated apex of the body 110.
(26) One or more solid-state light emitter 150 is/are mounted on a circular substrate 160. In some embodiments, the substrate 160 comprises a circular MCPCB (Metal Core Printed Circuit Board). As is known a MCPCB comprises a layered structure composed of a metal core base, typically aluminum, a thermally conducting/electrically insulating dielectric layer and a copper circuit layer for electrically connecting electrical components in a desired circuit configuration. The metal core base of the MCPCB 160 is mounted in thermal communication with the upper surface of the conical pedestal 130 with the aid of a thermally conducting compound such as for example a material containing a standard heat sink compound containing beryllium oxide or aluminum nitride.
(27) Each solid-state light emitter 150 can comprise a gallium nitride-based blue light emitting LED operable to generate blue light with a dominant wavelength of 455 nm-465 nm. As indicated in
(28) The lamp 100 further comprises a photoluminescence wavelength conversion component 180 that includes one or more photoluminescence materials. The photoluminescence wavelength conversion component 180 comprises an elongate component 190 having a constant cross section and a reflector 200 on the end of the component 190 distal to the LEDs 150. The reflector 200 has a shape that corresponds to the outer shape of the component 190, that is circular in this example, thereby reducing or eliminating light emission from the end of the component. By reducing or eliminating light emission from the end of the component reduces the overall emission intensity along the axis 170 of the lamp.
(29) In some embodiments, the photoluminescence materials comprise phosphors. For the purposes of illustration only, the following description is made with reference to photoluminescence materials embodied specifically as phosphor materials. However, the invention is applicable to any type of photoluminescence material, such as either phosphor materials or quantum dots. A quantum dot is a portion of matter (e.g. semiconductor) whose excitons are confined in all three spatial dimensions that may be excited by radiation energy to emit light of a particular wavelength or range of wavelengths.
(30) The one or more phosphor materials can include an inorganic or organic phosphor such as for example silicate-based phosphor of a general composition A.sub.3Si(O,D).sub.5 or A.sub.2Si(O,D).sub.4 in which Si is silicon, O is oxygen, A includes strontium (Sr), barium (Ba), magnesium (Mg) or calcium (Ca) and D includes chlorine (Cl), fluorine (F), nitrogen (N) or sulfur (S). Examples of silicate-based phosphors are disclosed in U.S. Pat. No. 7,575,697 B2 Silicate-based green phosphors, U.S. Pat. No. 7,601,276 B2 Two phase silicate-based yellow phosphors, U.S. Pat. No. 7,655,156 B2 Silicate-based orange phosphors and U.S. Pat. No. 7,311,858 B2 Silicate-based yellow green phosphors. The phosphor can also include an aluminate-based material such as is taught in co-pending patent application US2006/0158090 A1 Novel aluminate-based green phosphors and U.S. Pat. No. 7,390,437 B2 Aluminate-based blue phosphors, an aluminum-silicate phosphor as taught in co-pending application US2008/0111472 A1 Aluminum-silicate orange-red phosphor or a nitride-based red phosphor material such as is taught in co-pending United States patent application US2009/0283721 A1 Nitride-based red phosphors and International patent application WO2010/074963 A1 Nitride-based red-emitting in RGB (red-green-blue) lighting systems. It will be appreciated that the phosphor material is not limited to the examples described and can include any phosphor material including nitride and/or sulfate phosphor materials, oxy-nitrides and oxy-sulfate phosphors or garnet materials (YAG).
(31) Quantum dots can comprise different materials, for example cadmium selenide (CdSe). The color of light generated by a quantum dot is enabled by the quantum confinement effect associated with the nano-crystal structure of the quantum dots. The energy level of each quantum dot relates directly to the size of the quantum dot. For example, the larger quantum dots, such as red quantum dots, can absorb and emit photons having a relatively lower energy (i.e. a relatively longer wavelength). On the other hand, orange quantum dots, which are smaller in size can absorb and emit photons of a relatively higher energy (shorter wavelength). Additionally, daylight panels are envisioned that use cadmium free quantum dots and rare earth (RE) doped oxide colloidal phosphor nano-particles, in order to avoid the toxicity of the cadmium in the quantum dots.
(32) Examples of suitable quantum dots include: CdZnSeS (cadmium zinc selenium sulfide), Cd.sub.xZn.sub.1-xSe (cadmium zinc selenide), CdSe.sub.xS.sub.1-x (cadmim selenium sulfide), CdTe (cadmium telluride), CdTe.sub.xS.sub.1-x (cadmium tellurium sulfide), InP (indium phosphide), In.sub.xGa.sub.1-x P (indium gallium phosphide), InAs (indium arsenide), CuInS.sub.2 (copper indium sulfide), CuInSe.sub.2 (copper indium selenide), CuInS.sub.xSe.sub.2-x (copper indium sulfur selenide), CuIn.sub.xGa.sub.1-xS.sub.2 (copper indium gallium sulfide), CuIn.sub.xGa.sub.1-xSe.sub.2 (copper indium gallium selenide), CuIn.sub.xAl.sub.1-xSe.sub.2 (copper indium aluminum selenide), CuGaS.sub.2 (copper gallium sulfide) and CuInS.sub.2xZnS.sub.1-x (copper indium selenium zinc selenide).
(33) The quantum dots material can comprise core/shell nano-crystals containing different materials in an onion-like structure. For example, the above described exemplary materials can be used as the core materials for the core/shell nano-crystals.
(34) The optical properties of the core nano-crystals in one material can be altered by growing an epitaxial-type shell of another material. Depending on the requirements, the core/shell nano-crystals can have a single shell or multiple shells. The shell materials can be chosen based on the band gap engineering. For example, the shell materials can have a band gap larger than the core materials so that the shell of the nano-crystals can separate the surface of the optically active core from its surrounding medium.
(35) In the case of the cadmiun-based quantum dots, e.g. CdSe quantum dots, the core/shell quantum dots can be synthesized using the formula of CdSe/ZnS, CdSe/CdS, CdSe/ZnSe, CdSe/CdS/ZnS, or CdSe/ZnSe/ZnS. Similarly, for CuInS.sub.2 quantum dots, the core/shell nanocrystals can be synthesized using the formula of CuInS.sub.2/ZnS, CuInS.sub.2/CdS, CuInS.sub.2/CuGaS.sub.2, CuInS.sub.2/CuGaS.sub.2/ZnS and so on.
(36) As shown in
(37)
(38) The reflector 200 can comprise a light reflective circular disc that is mounted to the end of the component such that covers the end face of the component. Conveniently the reflector 200 can comprise an injection molded part composed of a light reflective plastics material. Alternatively the reflector can comprise a metallic component or a component with a metallization surface.
(39) Since the component has a constant cross section it can be readily manufactured using an extrusion method. The component can be formed using a light transmissive thermoplastics (thermosoftening) material such as polycarbonate, acrylic or a low temperature glass using a hot extrusion process. Alternatively the component can comprise a thermosetting or UV curable material such as a silicone or epoxy material and be formed using a cold extrusion method. A benefit of extrusion is that it is relatively inexpensive method of manufacture.
(40) Alternatively the component can be formed by injection molding though such a method tends to be more expensive than extrusion. Since the component has a constant cross section it can be formed using injection molding without the need to use an expensive collapsible former. In other embodiments the component can be formed by casting.
(41) Another possible approach is to manufacture the component is by forming a flexible sheet material to include the phosphor and/or quantum dots, and then rolling the sheet material into the desired shape and dimensions for the component. The phosphor may be applied as a layer onto the sheet material, e.g., by coating, printing, or other suitable deposition methods. Alternatively, the phosphor may be incorporated within the material of the flexible sheet.
(42) In operation the LEDs 150 generate blue excitation light a portion of which excite the photoluminescence material within the wavelength conversion component 180 which in response generates by a process of photoluminescence light of another wavelength (color) typically yellow, yellow/green, orange, red or a combination thereof. The portion of blue LED generated light combined with the photoluminescence material generated light gives the lamp an emission product that is white in color.
(43) A particular benefit of photoluminescence components in accordance with embodiments of the invention is that as well as improving the emission distribution pattern they can also improve overall light emission efficiency. For example preliminary tests indicate that the hollow tubular wavelength conversion components described can gives a total light emission that is greater than the known wavelength conversion components. It is believed that the increase in emission efficiency results from the component having a high aspect ratio which it believed reduces the possibility of re-absorption of light by the LED(s) positioned at the opening of the component.
(44) A further advantage of photoluminescence wavelength conversion components in accordance with the invention is that their light emission resembles a filament of a conventional incandescent light bulb.
(45)
(46)
(47)
(48) Whilst the foregoing photoluminescence components comprise a hollow component (i.e. the central region or bore does not include a light transmissive medium) in other embodiments the component can comprise a component having a solid light transmissive core. A component with a light transmissive core can further increase light emission by eliminating or significantly any air interface between the wavelength conversion component 180 and the LEDs 150. This is particularly so for light travelling in a radial direction between walls of the component.
(49)
(50) Such a component can be formed by co-extrusion of the core 270 and phosphor layers 190. Alternatively the component can be manufactured by fabricating the component of
(51) Where the component comprises a solid component, the reflector 200 can comprise a coating, such as a light reflective paint or metallization layer, that is applied directly to the end face of the component.
(52)
(53)
(54) Whilst the invention arose in relation to and finds particular application to light bulbs, photoluminescence wavelength conversion components of the invention can be utilized in other light emitting devices and lighting arrangements such as for example linear lamps.
(55)
(56)
(57) In each of foregoing embodiments the components comprises a first proximal end for receiving light and a reflector on the distal end. It is envisioned in further embodiments that each end of the component is configured to receive light thereby eliminating the need for the reflector.
(58)
(59)
(60)
(61) It will be appreciated that the invention is not limited to the exemplary embodiments described and that variations can be made within the scope of the invention. For example whilst in the embodiments described the photoluminescence wavelength conversion component has a circular cross section, the component can have other cross sections such as elliptical, triangular, square, pentagonal, hexagonal.