Laser-based light source with heat conducting outcoupling dome
10443800 ยท 2019-10-15
Assignee
Inventors
Cpc classification
F21Y2115/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2115/15
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V13/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01S5/0087
ELECTRICITY
F21S41/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S45/47
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/68
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S41/176
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21K9/66
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V9/35
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V9/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S41/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V29/502
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V29/70
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V13/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S41/285
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21V13/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S41/176
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V9/35
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S41/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S45/47
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S41/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V9/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The invention describes a laser-based light source comprising: a laser being arranged to emit laser light, a ceramic light converter being adapted to convert a part of the laser light to converted light, a light outcoupling dome with a base area of at least 2.5*10.sup.5 m.sup.2 comprising a material with a thermal conductivity of more than 25 W/(m*K), wherein a bonding area of the light outcoupling dome of at least 8*10.sup.3 m.sup.2 is adhesive-free bonded to the ceramic light converter, wherein the base area is at least 25 times larger than an area of the ceramic light converter being arranged to be illuminated by the laser, a substrate thermally coupled to the light outcoupling dome,
wherein the light outcoupling dome comprises a reflective structure being arranged such that converted light emitted with an angle larger than =65 with respect to an optical axis of the light outcoupling dome is reflected back in the direction of the ceramic light converter. The invention further relates to a vehicle headlight comprising such a laser-based light source.
Claims
1. A laser-based light source comprising: a laser being arranged to emit laser light with a laser peak emission wavelength, a ceramic light converter being adapted to convert a part of the laser light to converted light, wherein a peak emission wavelength of the converted light is in a longer wavelength range than the laser peak emission wavelength, a light outcoupling dome with a base area of at least 2.5*10.sup.5 m.sup.2 comprising a material with a thermal conductivity of more than 25 W/(m*K), wherein a bonding area of the base area of the light outcoupling dome of at least 8*10.sup.3 m.sup.2 is adhesive-free bonded to the ceramic light converter, wherein the base area is at least 25 times larger than an area of the ceramic light converter being arranged to be illuminated by the laser, a substrate thermally coupled to the light outcoupling dome, wherein the light outcoupling dome comprises an optical axis extending through a center point of the base area and through a top of the light outcoupling dome, a center of the ceramic light converter is arranged near to or on the optical axis of the light outcoupling dome, the light outcoupling dome comprises a reflective structure covering a rim of the light outcoupling dome around the base area, and the reflective structure is arranged such that converted light emitted into the light outcoupling dome with an angle larger than =65 with respect to the optical axis of the light outcoupling dome is reflected back in the direction of the ceramic light converter.
2. The laser-based light source according to claim 1, wherein the light outcoupling dome comprises a semi-sphere of sapphire, wherein the ceramic light converter is thermal bonded to the light outcoupling dome, wherein the laser is adapted to emit laser light with a blue laser peak emission wavelength through an opening of the substrate to the ceramic light converter such that at least 50% of the converted light is emitted via the light outcoupling dome.
3. The laser-based light source according to claim 2, wherein the ceramic light converter comprises a yellow phosphor garnet, and wherein the laser-based light source is adapted to emit white light comprising at least a part of the converted light and at least a part of transmitted laser light transmitted through the ceramic light converter.
4. The laser-based light source according to claim 1, wherein the laser-based light source comprises a side coating attached to a side of the ceramic light converter, wherein the side of the ceramic light converter is inclined with respect to the bonding area.
5. The laser-based light source according to claim 1, wherein an emission cone of the laser light is adapted to the angle defined by means of the reflective structure such that the transmitted laser light and the converted light emitted via the outcoupling dome overlap within the angle around the optical axis.
6. The laser-based light source according to claim 5, wherein the laser-based light source comprises a light guide being adapted to guide the laser light from the laser to the ceramic light converter, wherein the light guide comprises a numerical aperture being adapted to define the emission cone of the transmitted laser light.
7. The laser-based light source according to claim 5, wherein the laser-based light source comprises a light deflection layer coupled to the ceramic light converter, wherein the light deflection layer is adapted to define the emission cone of the transmitted laser light.
8. The laser-based light source according to claim 1, wherein the laser-based light source comprises a partly reflective structure coupled to the light outcoupling dome, wherein an optical transmittance of the partly reflective structure depends in a predefined wavelength range from the laser peak emission wavelength such that a color point of mixed light comprising a part of the converted light and a part of the laser light is stabilized.
9. The laser-based light source according to claim 1, wherein the light outcoupling dome comprises a semi-sphere of sapphire, wherein the ceramic light converter comprises a yellow phosphor garnet thermal bonded to the light outcoupling dome, wherein the laser is adapted to emit laser light with a blue laser peak emission wavelength through the light outcoupling dome to the ceramic light converter, and wherein the laser-based light source is adapted to emit white light comprising at least a part of the converted light and at least a part of the laser light.
10. The laser-based light source according to claim 9, wherein the ceramic light converter is directly bonded to the substrate by means of a bonding layer.
11. The laser-based light source according to claim 1, wherein a shield is attached to the light outcoupling dome such that laser light is blocked if the ceramic light converter.
12. A vehicle headlight comprising at least one laser-based light source according to claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.
(2) The invention will now be described, by way of example, based on embodiments with reference to the accompanying drawings.
(3) In the drawings:
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(13) In the Figures, like numbers refer to like objects throughout. Objects in the Figures are not necessarily drawn to scale.
DETAILED DESCRIPTION OF EMBODIMENTS
(14) Various embodiments of the invention will now be described by means of the Figures.
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(16) The good thermal coupling between the ceramic light converter 134 and the light outcoupling dome 136 reduces the risk of thermal quenching of the ceramic light converter 134. The semispherical shape of the light outcoupling dome 136 decreases the probability of total internal reflection at the semispherical surface of the light outcoupling dome 136 because most of the light reaches the semispherical surface at small angles with respect to a normal to the semispherical surface at the respective surface point.
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(18) Line 64 shows the results of the simulation if the radius Rc of the hole in the substrate 131 is the same as the radius Ri of the ceramic light converter 134. Line 65 shows a result of the simulation if the radius Rc of the hole in the substrate 131 is 100 m larger than the radius Ri of the ceramic light converter 134. Line 66 shows the results of the simulation if the radius Rc of the hole in the substrate 131 is the same as the radius Ri of the ceramic light converter 134 but the thickness of the adhesive between the substrate 131 and the sapphire light outcoupling dome 136 is reduced to 1 m instead of 10 m. Line 67 shows an 1/r dependence as a reference. The simulations teach the following: enlarging the hole opening Rc in the substrate 131 slightly raises the thermal resistance the interface between the substrate 131 and the light outcoupling dome is uncritical because there is essentially no difference between line 64 and line 66 the thermal resistance is approximately proportional to 1/r
(19) Further simulations with increased radius Ro of the light outcoupling dome 136 show that the radius Ro of the dome does not matter as long as the radius Ro is at least 500 m. The thermal performance does not improve if the radius of the light outcoupling dome 136 increases, for example, from 500 m to 1000 m. However, the optical performance depends on the ratio between the radius Ri of the ceramic light converter 134 and the radius Ro of the light outcoupling dome 136. The radius Ro of the light outcoupling dome 136 is preferably at least five times larger than the radius Ri of the ceramic light converter 134, more preferably at least seven times larger.
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(21) The simulation results shown in
(22) TABLE-US-00001 TABLE 1 Phosphor Phosphor Rth total Target radius (mm) thickness (m) (K/W) Glued on Al 0.282 50 44 Sintered on sapphire 0.282 50 43 Sintered on sapphire 0.200 25 55 Sintered on sapphire 0.150 25 80 Sintered on sapphire 0.100 25 142 Glued on Al 0.150 25 116 Soldered 0.100 25 53
(23) The table above shows the calculated thermal resistance (K/W) for several target types. There are two types of targets. The first target is a combination of the ceramic light converter 134 with an Aluminum mirror. The ceramic light converter 134 may be glued or soldered to the Aluminum mirror. The table shows that if a ceramic light converter 134 of 500.sup.2 m.sup.2 (equivalent to Ri=282 m) is used, the sintering approach is comparable (Rth=43 K/W) to the gluing approach (44 K/W) in the optimum case with a glue layer with a thickness of 1 m. As soon as the target is smaller, the sintering approach is better than gluing. In case of a radius Ri=150 m the sintering approach results in a thermal resistance of 80 K/W, while gluing on the aluminum mirror results in a thermal resistance of 116 K/W. Soldering is even much better, yielding, at Ri=100 m, a thermal resistance of 53 K/W as compared to 142 K/W with sintering. But soldering requires a reflective target. That means that the converted light 20 emitted by means of the ceramic light converter 134 is emitted to the same side where the laser 110 is mounted (see
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(25) The second laser-based light source 100 further comprises a shield 140 which is arranged on top of the light outcoupling dome 136. The shield 140 may be a circular coating around the top of the light outcoupling dome 136. This shield 140 is positioned such that in case of removal of the ceramic light converter 134 laser light 10 is reflected or absorbed by means of the shield 140. The shield 140 reduces the risk that laser light 10 passes the light outcoupling dome 136 without broadening or light conversion by means of the ceramic light converter 134. The size and shape of the shield may therefore be adapted to the size and shape of the emission cone of laser light 10 entering the light outcoupling dome 136.
(26) The second laser-based light source 100 further comprises a side coating 132. The side coating is arranged to reflect converted light 20 such that losses of converted light via the side surfaces of the ceramic light converter 134 is reduced.
(27) The reflective structure 137 is most efficient if the size of the radius Ro of the light outcoupling dome 136 in comparison to the radius Ri of the ceramic light converter 134 is arranged such that essentially all converted light emitted at larger angles than is reflected back to the bonding area at which the ceramic light converter 134 is bonded to the light outcoupling dome 136. The radius Ro of the light outcoupling dome 136 is preferably at least five times larger than the radius Ri of the ceramic light converter 134.
(28) Simulation results prove the efficiency of the laser based light sources 100 shown in
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(33) Now it is considered that the partly reflective structure 138 (multilayer coating) is added with a tailored spectral transmittance (line 56; see also
(34) With the partly reflective structure 138 covering the semispherical surface of the light outcoupling dome 136, the blue fraction and yellow fraction will behave differently. It can be shown that the resulting blue fraction (output blue power divided by [output blue+output yellow]) will be flat (line 97). This means that the color point will not change, no matter what wavelength the laser light 10 has, as long as it is below 455 nm.
(35) However, the reflected blue laser light 10 cannot be totally converted to yellow converted light 20 but will be partially lost, due to practical limitations of the ceramic light converter. The price of the stable color, therefore, is a reduction of the total radiative flux (line 96). This effect is tolerable: For example, if the blue laser light 10 has a wavelength of 440 nm, i.e. 15 nm below the operation wavelength, the total flux is reduced to 0.9, i.e. by only 10%. This is acceptable by at the same time avoiding an otherwise intolerable color shift: Without the partly reflective structure 138, the blue fraction of the mixed light emitted by the laser-based light source 100 would raise from 17% to 41% (line 94).
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(37) While the invention has been illustrated and described in detail in the drawings and the foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive.
(38) From reading the present disclosure, other modifications will be apparent to persons skilled in the art. Such modifications may involve other features which are already known in the art and which may be used instead of or in addition to features already described herein.
(39) Variations to the disclosed embodiments can be understood and effected by those skilled in the art 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 of elements or steps. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
(40) Any reference signs in the claims should not be construed as limiting the scope thereof.
LIST OF REFERENCE NUMERALS
(41) 10 laser light 11 reflected laser light 12 transmitted laser light 20 converted light 51 absorption 52 wavelength 53 spectral transmittance 55 absorption coefficient of a YAG:Ce phosphor 56 transmittance of partially reflective structure 61 thermal resistance (K/W) 62 phosphor radius Ri (m) 64 thermal resistance for Rc=Ri and 10 m glue 65 thermal resistance for Rc=Ri+100 m 66 thermal resistance for Rc=Ri and 1 m glue 67 1/r dependence 74 thermal resistance at a phosphor thickness of 50 m 75 thermal resistance at a phosphor thickness of 25 m 76 thermal resistance of glue layer of 1 m 91 operation wavelength of 455 nm 92 material absorption (arbitrary units) 93 sample conversion 94 blue fraction (without partly reflective structure) 95 total power (without partly reflective structure) 96 total power (with partly reflective structure) 97 blue fraction (with partly reflective structure) 100 laser-based light source 110 laser 115 optical device 120 light guide 131 substrate 132 side coating 133 light deflection layer 134 ceramic light converter 135 bonding layer 136 light outcoupling dome 136a optical axis 137 reflective structure 138 partly reflective structure 139 window 140 shield dome opening angle Ri phosphor radius Rc radius of substrate opening Ro radius of dome