System and method for selected pump LEDs with multiple phosphors
11611023 · 2023-03-21
Assignee
Inventors
- Aurelien J. F. David (San Francisco, CA, US)
- Arpan Chakraborty (Los Angeles, CA, US)
- Michael Ragan Krames (Los Altos, CA, US)
- Troy Trottier (Los Angeles, CA, US)
Cpc classification
H01L33/504
ELECTRICITY
H01L2924/0002
ELECTRICITY
C09K11/77348
CHEMISTRY; METALLURGY
H01L2924/00
ELECTRICITY
H01L2924/0002
ELECTRICITY
H01L33/08
ELECTRICITY
H01L2924/00
ELECTRICITY
Y02B20/00
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H01L33/08
ELECTRICITY
Abstract
An LED pump light with multiple phosphors is described. LEDs emitting radiation at violet and/or ultraviolet wavelengths are used to pump phosphor materials that emit other colors. The LEDs operating in different wavelength ranges are arranged to reduce light re-absorption and improve light output efficiency.
Claims
1. A light source for emitting emitted light, said light source comprising: a plurality of light emitting diodes for emitting LED light, and comprising at least one first LED having a first peak wavelength in a range 405-430 nm, and at least one second LED having a second peak wavelength which is longer than the first peak wavelength; and one or more wavelength-converting materials for converting a portion of said LED light into converted light, wherein said emitted light is a combination of unconverted light of said LED light and said converted light, wherein at least one of said one or more wavelength-converting materials is a combination of phosphor and quantum dots.
2. The light source of claim 1, wherein said at least one second LED is a blue LED.
3. The light source of claim 1, wherein said at least one of said one or more wavelength-converting materials emits red light.
4. The light source of claim 1, wherein said at least one of said one or more wavelength-converting materials absorbs a portion of LED light being emitted by said at least one first LED.
5. The light source of claim 1, said at least one of said one or more wavelength-converting materials is disposed over said at least one first LED.
6. The light source of claim 1, wherein said one or more wavelength-converting materials comprise a green phosphor and a red phosphor.
7. The light source of claim 1, wherein said one or more wavelength-converting materials do not include a blue phosphor.
8. The light source of claim 1, wherein said at least one first LED is characterized by an internal quantum efficiency of at least 70% when operated at a current density of 100 A.Math.cm−2.
9. The light source of claim 1, wherein said emitted light is white light.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(9) This invention is directed to lighting systems and to the provision of LED pump light with multiple phosphors. LEDs emitting radiation at violet and/or ultraviolet wavelengths are used to pump phosphor materials that emit different colors. Preferably the pump LEDs have a peak emission wavelength of about 405 to 430 nm under normal operating conditions.
(10) As mentioned above, conventional LED lights sources are often inadequate. For example, one of the most-common approaches to generating high-CRI white LED light consists of LED devices emitting in the 440-470 nm range (often referred to as pump LEDs), which excite two phosphors: a yellow/green phosphor and a red phosphor. This approach is convenient because some yellow/green phosphors, such as Ce:YAG, exhibit high quantum efficiency.
(11) Unfortunately, this approach is also constraining. YAG-based phosphors can only be efficiently excited in a narrow spectral range around 460 nm, limiting the wavelength range of the pump LEDs that can be employed. While high internal quantum efficiency (IQE) LED devices can be created at such wavelengths at low current density, their IQE falls rapidly at high current density. This is due to two effects: (a) the presence of large piezoelectric fields which reduce the carrier overlap and therefore increase the carrier lifetime, shifting the IQE curve to lower current density (ref); and (b) the challenges associated with thick active regions emitting around 445 nm (due to both strain-related growth limitations with thick InGaN layers and the difficulty with carrier spreading in a multi-quantum-well system).
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(13) The blue light from the pump LED contributes to the white spectrum. Therefore, the amount of blue light that is transmitted by the phosphors needs to be well-controlled to achieve a given CCT. Variations in the wavelength of the pump LED need to be accounted for in the phosphor composition/loading. Accounting for the differences in wavelength can be a challenging task when manufacturing white LEDs.
(14) State-of-the-art results for 440-nm pump LEDs can be found in the article “White light emitting diodes with super-high luminous efficacy”, Y. Narukawa et al, J. Phys. D 43, 354002 (2010). At room temperature and a current density of about 100 A/cm.sup.2, an external quantum efficiency of 65% is reported. Assuming an extraction efficiency of about 90% and a performance drop of about 10% between room temperature and a 100 C junction temperature, this corresponds to an IQE of about 65% at 100 A/cm.sup.2 and 100 C.
(15) Another conventional approach consists in using a pump LED whose emission peak is in the 395-405 nm range to pump a system of three or four phosphors. This is advantageous because 400 nm pump LEDs typically retain higher performance at a higher current density than 445 nm pump LEDs, presumably due to the lower piezoelectric fields and to the thick active regions.
(16) Employing an LED emitter whose final spectra is minimally affected (in color or brightness) by the presence or absence of the emitter wavelength in the final spectra allows for very stable performance over drive currents and temperatures. Proper selection of color-stable phosphor materials for the devices range of operation (e.g. a 405 nm emitter's spectral weight) is only 1.5% that of a 450 nm emitter. A 420 nm emitter's spectral weight is still only 10% of that of a 450 nm emitter. Stability in color and flux of a finished phosphor-converted LED is increased dramatically over a traditional blue pump device where as much as 20% of the final spectrum is comprised of the underlying emitter at 450 nm.
(17) The elimination of the need to target a certain amount of emitter light leakage in the final spectra also offers improved color yield in a manufacturing environment. The manufacturing phosphor deposition process for an about 405 nm to 430 nm pump device can accept more process variance without sacrificing large-volume color repeatability. In turn, this allows a manufacturing process to run with higher throughput without loss in repeatability.
(18) Use of three or more component colors (chip emission and at least two phosphors) offers a larger tunable color gamut for a phosphor-converted LED device than does a two-component color system. A large range of tunable colors and color rendering indices become available. A two-color component white LED will only have one possible cross section with the Planckian curve (one point to achieve a balanced white spectrum) whereas a three or more color system allows for infinite tunability along the Planckian curve.
(19) This approach, however, suffers from various limitations:
(20) 1. The Stokes loss between the pump wavelengths and the phosphors wavelengths is larger, so more energy is lost in the phosphor down-conversion process. The comparatively larger band gap of a 400 nm pump LED causes a larger operation voltage. The reduced carrier confinement in the active region of a 400 nm pump LED makes it easier for carriers to escape, and therefore decreases the high-temperature performance. Most materials have a significantly larger absorption at 400 nm than at 445 nm (this is the case for high-reflectivity metals such as Al and Ag which are commonly used in LEDs, of silicones, of some substrates such as GaN or SiC, and of Au wirebonds.) which decreases the light-extraction efficiency.
(21) 2. There has not been focused development on phosphors for use with 380-430 nm excitation light. This places the performance levels of the available phosphor materials behind the state-of-the-art phosphor performance enjoyed by LED manufacturers employing 450 nm pump LEDs for use with materials such as Y.sub.3Al.sub.5O.sub.12:Ce.sup.3+ (YAG-yellow) and CaAlSiN:Eu.sup.2+ (red) which have had both time and pressure applied to their improvements.
(22) 3. Due to this offset in state-of-the-art phosphor material performance, not all of the available phosphors can be used in high performance LED devices. Prime examples are blue phosphors which are not suitable for use with all chip-emission wavelengths. The absorption characteristics of two blue-emitting phosphors are shown in
(23) This invention provides white LED light sources with high performance. Among other things, the invention provides a new approach to high-CRI white LEDs. For example, the white LED light source comprises pump LED(s) whose peak emission is in the range of about 405 nm to 430 nm and a system of three or more phosphors (such as blue, green, and red). A substantially white spectrum is produced by the phosphor emission.
(24) One advantage of the invention is that a pump LED in the range of about 405 nm to 430 nm can display a very high IQE at high carrier density (similar to a 400 nm pump LED) due to the moderate strain and piezoelectric fields. The carrier confinement in the active region, on the other hand, is significantly improved so that the high-temperature performance is not compromised. The lower band gap compared to a 400 nm LED also enables a lower forward voltage. Therefore, the range of about 405 nm to 430 nm is optimal from the standpoint of pump LED performance. High IQE performance for such LEDs (at a current density of 100 A/cm.sup.2 and a junction temperature 100 C) can be better than 70% and even exceed 90%. This is to be compared to about 65% for state-of-the art LEDs emitting at 440 nm as described in the prior art.
(25) In addition, optical absorption in most materials is significantly reduced between 400 nm and about 405 nm to 430 nm, yielding overall larger light-extraction efficiency. Also, as explained above, the use of three or more phosphors to generate white light is advantageous in terms of color control and process stability. Blue phosphors are available with strong absorption in the range of about 405 nm to 430 nm, and with high quantum efficiency. Some examples of blue-emitting phosphors with strong absorption in this wavelength range are BaMgAl.sub.10O17:Eu.sup.2+, Sr.sub.10 (PO.sub.4).sub.6Cl.sub.2:E, LaAl(Si.sub.6−zAl.sub.z)N.sub.10−zO.sub.z:Ce.sup.3+, a-Sialon:Ce.sup.3+, (Y,La)—Si—O—N:Ce.sup.3+, Gd.sub.1−xSr.sub.2+xAlO.sub.5−xF.sub.x:Ce.sup.3+. The Stokes loss is also mitigated in comparison to a 400 nm pump LED.
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(27) Depending on the application, the encapsulant may include various types of materials. In a preferred embodiment, the encapsulant is specifically configured to improve light-extraction efficiency. For example, the encapsulant material can comprise polymeric species. In a preferred embodiment, the pump LED source emits radiation in the wavelength range from about 405 nm to 430 nm and pumps three phosphors (e.g., a blue, a green, and a red phosphor) that are mixed together, and the phosphor mix converts a substantial fraction of the pump LED source light to longer-wavelength light. Of course, the phosphor mix may contain additional phosphors, e.g. an amber phosphor can be added to increase CRI.
(28) In various embodiments, the wavelength emitted by the LED changes due to changes in temperature. For example, a pump LED emits radiation at a wavelength of about 398 nm at room temperature. When temperature increases to about 120° C., the pump LED emits radiation about 405 nm. Typically, high current and/or high temperature are the main causes of wavelength shift. For example, for each increase of 23° C. in operating temperature, the wavelength of the radiation emitted by the pump LED increases by 1 nm. The encapsulant and the phosphor material used in various embodiments of the invention can compensate for the wavelength shift.
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(32) In a preferred embodiment, the LEDs emit radiation in substantially the same color (e.g., about 405 nm to 430 nm in wavelength), and the radiation from the LEDs pumps the single-color phosphor materials that are in different spatial locations. In return, the colored phosphor materials emit colored light. For example, the phosphor materials, as shown in
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(34) Depending on the application, the LEDs can be arranged in array geometry using several pump LEDs in combination with blue or red LEDs that are not configured to pump phosphor material. It is to be appreciated that the arrangement of LEDs as shown in
(35) Different arrangements of phosphor materials and LED devices enable different light colors to be obtained. In a preferred embodiment, the LED devices are grown on a non-polar or semi-polar substrate. In certain embodiments, the LED devices can be grown on a low-dislocation-density substrate (<1×10.sup.7 dislocations/cm.sup.2) to enable reliable operation at high current density and high temperature.
(36) Wavelength conversion materials can be ceramic or semiconductor particle phosphors, ceramic or semiconductor plate phosphors, organic or inorganic down converters, up converters (anti-stokes), nano-particles and other materials which provide wavelength conversion. Some examples are listed below
(37) (Sr.sub.n,Ca.sub.1−n).sub.10(PO.sub.4).sub.6*B.sub.2O.sub.3:Eu.sup.2+ (wherein 0≤n≤1)
(38) (Ba,Sr,Ca).sub.5(PO.sub.4).sub.3(Cl,F,Br,OH):Eu.sup.2+,Mn.sup.2+
(39) (Ba,Sr,Ca)BPO.sub.5:Eu.sup.2+,Mn.sup.2+
(40) Sr.sub.2Si.sub.3O.sub.8*2SrCl.sub.2:Eu.sup.2+
(41) (Ca,Sr,Ba).sub.3MgSi.sub.2O.sub.8:Eu.sup.2+, Mn.sup.2+
(42) BaAl.sub.8O.sub.13:Eu.sup.2+
(43) 2SrO*0.84P.sub.2O.sub.5*0.16B.sub.2O.sub.3:Eu.sup.2+
(44) (Ba,Sr,Ca)MgAl.sub.10O.sub.17:Eu.sup.2+,Mn.sup.2+
(45) K.sub.2SiF.sub.6:Mn.sup.4+
(46) (Ba,Sr,Ca)Al.sub.2O.sub.4:Eu.sup.2+
(47) (Y,Gd,Lu,Sc,La)BO.sub.3:Ce.sup.3+,Tb.sup.3+
(48) (Ba,Sr,Ca).sub.2(Mg,Zn)Si.sub.2O.sub.7:Eu.sup.2+
(49) (Mg,Ca,Sr,Ba,Zn).sub.2Si.sub.1−xO.sub.4−2x:Eu.sup.2+ (wherein 0≤x≤0.2)
(50) (Sr,Ca,Ba)(Al,Ga).sub.2S.sub.4:Eu.sup.2+
(51) (Ca,Sr).sub.8(Mg,Zn)(SiO.sub.4).sub.4Cl.sub.2:Eu.sup.2+,Mn.sup.2+
(52) Na.sub.2Gd.sub.2B.sub.2O.sub.7:Ce.sup.3+,Tb.sup.3+
(53) (Sr,Ca,Ba,Mg,Zn).sub.2P.sub.2O.sub.7:Eu.sup.2+,Mn.sup.2+
(54) (Gd,Y,Lu,La).sub.2O.sub.3:Eu.sup.3+,Bi.sup.3+
(55) (Gd,Y,Lu,La).sub.2O.sub.2S:Eu.sup.3+,Bi.sup.3+
(56) (Gd,Y,Lu,La)VO.sub.4:Eu.sup.3+,Bi.sup.3+
(57) (Ca,Sr)S:Eu.sup.2+,Ce.sup.3+
(58) (Y,Gd,Tb,La,Sm,Pr,Lu).sub.3(Sc,Al,Ga).sub.5−nO.sub.12−3/2n:Ce.sup.3+ (wherein 0≤n≤0.5)
(59) ZnS:Cu+,Cl−
(60) (Y,Lu,Th).sub.3Al.sub.5O.sub.12:Ce.sup.3+
(61) ZnS:Cu+,Al3+
(62) ZnS:Ag+,Al3+
(63) ZnS:Ag+,Cl−
(64) (Ca,Sr)Ga.sub.2S.sub.4:Eu.sup.2+
(65) SrY.sub.2S.sub.4:Eu.sup.2+
(66) CaLa.sub.2S.sub.4:Ce.sup.3+
(67) (Ba,Sr,Ca)MgP.sub.2O.sub.7:Eu.sup.2+,Mn.sup.2+
(68) (Y,Lu).sub.2WO.sub.6:Eu.sup.3+,Mo.sup.6+
(69) CaWO.sub.4
(70) (Y,Gd,La).sub.2O.sub.2S:Eu.sup.3+
(71) (Y,Gd,La).sub.2O.sub.3:Eu.sup.3+
(72) (Ba,Sr,Ca).sub.nSi.sub.nN.sub.n:Eu.sup.2+ (where 2n+4=3n)
(73) Ca.sub.3(SiO.sub.4)Cl.sub.2:Eu.sup.2+
(74) (Y,Lu,Gd).sub.2,Ca.sub.nSi.sub.4N.sub.6+nC.sub.1−n:Ce.sup.3+, (wherein 0≤n≤0.5)
(75) (Lu,Ca,Li,Mg,Y) alpha-SiAlON doped with Eu.sup.2+ and/or Ce.sup.3+
(76) (Ca,Sr,Ba)SiO.sub.2N.sub.2:Eu.sup.2+,Ce.sup.3+
(77) (Sr,Ca)AlSiN.sub.3:Eu.sup.2+
(78) CaAlSi(ON).sub.3:Eu.sup.2+
(79) Sr.sub.10(PO.sub.4).sub.6Cl.sub.2:Eu.sup.2+
(80) (BaSi)O.sub.12N.sub.2:Eu.sup.2+
(81) SrSi.sub.2(O,Cl).sub.2N.sub.2:Eu.sup.2+
(82) (Ba,Sr)Si.sub.2(O,Cl).sub.2N.sub.2:Eu.sup.2+
(83) LiM.sub.2O.sub.8:Eu.sup.3+ where M=(W or Mo)
(84) In the list above, it is understood that when a phosphor has two or more dopant ions (i.e. those ions following the colon in the above phosphors), this means that the phosphor has at least one (but not necessarily all) of those dopant ions within the material. That is, as understood by those skilled in the art, this type of notation means that the phosphor can include any or all of those specified ions as dopants in the formulation.
(85) In certain embodiments, quantum-dot-based phosphors are used for color conversion purposes. Quantum dot materials are a family of semiconductor and rare earth doped oxide nanocrystals whose size and chemistry determine their luminescent characteristics. Typical chemistries for the semiconductor quantum dots include well known (ZnxCd1-x) Se [x=0..1], (Znx,Cd1-x)Se[x=0..1], Al(AsxP.sub.1−x) [x=0..1], (Znx,Cd1-x)Te[x=0..1], Ti(AsxP1-x) [x=0..1], In(AsxP1-x) [x=0..1], (AlxGa1-x)Sb [x=0..1], (Hgx,Cd1-x)Te[x=0..1] zincblende semiconductor crystal structures. Published examples of rare-earth doped oxide nanocrystals include Y2O3:Sm3+, (Y,Gd)2O3:Eu3+, Y2O3:Bi, Y2O3:Tb, Gd2SiO5:Ce, Y2SiO5:Ce, Lu2SiO5:Ce, Y3Al5)12:Ce but should not exclude other simple oxides or orthosilicates.
(86) In certain embodiments, the present invention provides a two-phosphor violet pumped white LED, which can be used for illumination. In a specific embodiment, a cyan phosphor and an orange phosphor are used with violet-pumped LED chips. For example, violet chips emitting radiation at wavelength of about 400-440 nm are provided. In this configuration, the emission of the two phosphors substantially determine the chromaticity and color quality of the white light. For example, color is determined primarily by the mix of two phosphors, and pump light leakage is typically minimal and not very eye-sensitive. This approach combines the advantages of reduced phosphor complexity and cost with the simplified color tuning of a two-phosphor system. Moreover, the low eye sensitivity of the violet pump ensures that color targeting in manufacturing with high yield is provided, unlike the case for blue-pumped systems in which case tight control over blue light leakage is necessary for maintaining tight control over chromaticity spread in high-volume manufacturing.
(87)
(88) While the above is a full description of the specific embodiments, various modifications, alternative constructions, and equivalents may be used. Therefore, the above description and illustrations should not be taken as limiting the scope of the present invention which is defined by the appended claims.