COMPACT LASER-BASED LIGHT GENERATING DEVICE
20230064361 · 2023-03-02
Inventors
- Hugo Johan Cornelissen (Escharen, NL)
- OLEXANDR VALENTYNOVYCH VDOVIN (MAARHEEZE, NL)
- ROBERT VAN ASSELT (VALKENSWAARD, NL)
- MARCELLUS JACOBUS JOHANNES VAN DER LUBBE (BEST, NL)
- GEORGES MARIE CALON (EINDHOVEN, NL)
- Rifat Ata Mustafa Hikmet (Eindhoven, NL)
- Ties Van Bommel (Horst, NL)
Cpc classification
F21Y2115/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V9/35
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G02B26/008
PHYSICS
F21V7/0033
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V7/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V9/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V9/38
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01S5/0087
ELECTRICITY
F21V29/50
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21V9/35
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V29/50
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V7/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The invention provides an arrangement (1) comprising a device (1000), wherein the device (1000) comprises a luminescent material comprising element (100) and a light transmissive element (200), wherein: (a) the device (1000) has a first device axis (A1); (b) the luminescent material comprising element (100) comprises a luminescent material (110) configured to emit luminescent material light (111) upon irradiation with first light (11), wherein the luminescent material comprising element (100) has a first length (L1) and a characteristic first dimension (D1) perpendicular to the first length (L1), wherein D1/L1<1; wherein the luminescent material comprising element (100) is configured at a non-zero first distance (r1) from the first device axis (A1), and wherein the luminescent material comprising element (100) at least partly surrounds the first device axis (A1); (c) the light transmissive element (200) is transmissive for the first light (11), wherein the light transmissive element (200) comprises a element light entrance part (201 and an element light escape part (202), wherein the element light escape part (202) and the luminescent material (110) are radiationally coupled; wherein one or more of the following applies: (i) the first device axis (A1) intersects the light transmissive element (200), and (ii) the light transmissive element (200) at least partly surrounds the first device axis (A1); and (d) the luminescent material comprising element (100) is in thermal contact with one or more of (a) the light transmissive element (200) and (b) an optional thermally conductive element (300).
Claims
1. An arrangement comprising a device, wherein the device comprises a luminescent material comprising element and a light transmissive element, wherein: the device has a first device axis; the luminescent material comprising element comprises a luminescent material configured to emit luminescent material light upon irradiation with first light, wherein the luminescent material comprising element has a first length and a characteristic first dimension perpendicular to the first length, wherein D1/L1<1; wherein the luminescent material comprising element is configured at a non-zero first distance from the first device axis, and wherein the luminescent material comprising element at least partly surrounds the first device axis; the light transmissive element is transmissive for the first light, wherein the light transmissive element comprises an element light entrance part and an element light escape part, wherein the element light escape part and the luminescent material are radiationally coupled; wherein one or more of the following applies: (i) the first device axis intersects the light transmissive element, and (ii) the light transmissive element at least partly surrounds the first device axis; and the luminescent material comprising element is in thermal contact with one or more of (a) the light transmissive element and (b) an optional thermally conductive element, wherein the light transmissive element comprises a dome-shaped body having a curved surface, wherein at least part of the curved surface comprises the element light entrance part, wherein the light transmissive element has a transmissive element axis, wherein the first device axis and the transmissive element axis coincide.
2. The arrangement according to claim 1, wherein the luminescent material comprising element is mechanically coupled to the light transmissive element and/or (b) the optional thermally conductive element.
3. The arrangement according to claim 1, wherein the luminescent material comprising element surrounds the first device axis and has a shape selected from circular, rectangular, hexagonal, octagonal, and decagonal.
4. The arrangement according to claim 1, wherein the luminescent material comprising element has a ring-like shape, wherein the first length is a circular length (Lc), wherein the characteristic first dimension is a height or width of the luminescent material comprising element, and D1/L1≤10.
5. The arrangement according to claim 1, wherein the luminescent material comprising element comprises a ceramic body comprising the luminescent material.
6. The arrangement according to claim 1, wherein the luminescent material comprising element comprises a polymeric body comprising the luminescent material distributed in the polymeric body, wherein the polymeric body comprises a polymeric material comprising silicone.
7. The arrangement according to claim 1, wherein the luminescent material comprising element is mounted on a sapphire rod.
8. The arrangement according to claim 1, wherein the dome-shaped body is configured to focus the first light on or in the luminescent material comprising element.
9. The arrangement according to claim 1, further comprising a first light source configured to generate the first light, wherein the first light source comprises a laser light source.
10. The arrangement according to claim 9, wherein the arrangement further comprises an actuator configured to rotate the luminescent material comprising element about the first device axis, and wherein during an operational mode of the arrangement the luminescent material comprising element rotates about the first device axis and the first light source is configured stationary relative to the rotating luminescent material comprising element.
11. The arrangement according to claim 1, wherein the luminescent material comprising element at least partly surrounds the light transmissive element, wherein the luminescent material comprising element comprises an element entrance part and an element escape part, wherein the element entrance part and element light escape part are radiationally coupled, and wherein the element entrance part is configured closer to the first device axis than the element escape part.
12. The arrangement according to claim 1, wherein the light transmissive element comprises a first reflective element configured to redirect first light from the first light source to the luminescent material comprising element and/or to redirect luminescent material light, wherein in an operational mode of the arrangement the first light source is configured stationary relative to the luminescent material comprising element.
13. The arrangement according to claim 12, wherein the first reflective element is configured to distribute the first light over the luminescent material comprising element, wherein the luminescent material comprising element has a ring-shaped structure, wherein the device further comprises a second optical element configured to beam shape the luminescent material light, wherein the second optical element has a half-toroidal lens or a half-toroidal reflector shape.
14. The arrangement according to claim 1, wherein the light transmissive element has a thermal conductivity of at least 10 W/m/K, and wherein the device further comprises the thermally conductive element, wherein the thermally conductive element is in thermal contact with the light transmissive element.
15. A luminaire or spotlight comprising the arrangement according to claim 1, wherein the arrangement comprises the first light source.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:
[0065]
[0066]
[0067]
[0068]
[0069]
[0070]
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0071] Pumping a ceramic phosphor with a focused blue laser diode can create a light source with 10-20 times higher luminance than a phosphor-converted white LED, thus enabling tighter beam angle spots or miniaturized luminaires. Low-power narrow-beam light sources consisting of a blue laser diode and a static ceramic Cerium-doped garnet phosphor plate exist. The luminance of the static phosphor configuration is limited by the limited heat spreading capacity of the phosphor, which causes thermal quenching of the phosphor when pumped above a certain blue laser power density. Mounting the phosphor on a spinning wheel may greatly improve the heat spreading, it may allow higher pumping power densities and may result in a higher luminance than in the static phosphor case. Such light engines can be found for instance be used in projection systems and stage lighting. Spinning wheel phosphor systems may be relatively bulky. Hence, there is a need for a laser-based light engine that is more compact than the current spinning phosphor wheel solutions, while providing a higher luminance than the current static phosphor solutions.
[0072] Amongst others, a compact laser light engine is described where blue laser light is converted by a ceramic phosphor that is mounted as a ring on a spinning transparent rod. The laser light enters the rod through a domed shaped end which focusses the light from the inside of the rod onto the phosphor. The spinning rod can be made from sapphire, providing improved heat management of the phosphor. This may provide a more compact system compared to a phosphor wheel solution, higher luminance compared to a static phosphor solution.
[0073] The principle of operation of a number of the herein described embodiments is shown in
[0074]
[0075] The luminescent material comprising element 100 comprises a luminescent material 110 configured to emit luminescent material light 111 upon irradiation with first light 11 (which may in embodiments be blue light). The luminescent material comprising element 100 has a first length L1 and a characteristic first dimension D1 perpendicular to the first length L1. For instance, in embodiments D1/L1<1. The luminescent material comprising element 100 is configured at a non-zero first distance r1 from the first device axis A1. Further, the luminescent material comprising element 100 at least partly surrounds the first device axis A1.
[0076] The light transmissive element 200 is transmissive for the first light 11. The light transmissive element 200 comprises an element light entrance part 201 (for the first light 11) and an element light escape part 202 (for the first light 11). The element light escape part 202 and the luminescent material 110 are radiationally coupled. One or more of the following may apply: (i) the first device axis A1 intersects the light transmissive element 200, and (ii) the light transmissive element 200 at least partly surrounds the first device axis A1. Here, the first, but also in fact, the second condition apply.
[0077] The luminescent material comprising element 100 may have a second external diameter (relative to the first device axis), such as the larger diameter of a ring. Further, the luminescent material comprising element 100 may have a third smallest diameter (relative to the first device axis) or internal diameter, such as the smaller diameter from a ring). The third diameter may especially in embodiments be equal to the first distance r1. The third diameter may in embodiments be smaller than the first external diameter, but the latter may be smaller than the second external diameter. For instance, the ring may have a larger diameter than the dome, for instance in embodiments 1-20% larger than the dome diameter. This might improve light extraction from the phosphor as light might also escape from the side facets of the phosphor, not only from the top surface.
[0078] The luminescent material comprising element 100 is in thermal contact with one or more of (a) the light transmissive element 200 and (b) an optional thermally conductive element 300.
[0079]
[0080] In embodiments, the luminescent material comprising element 100 surrounds the first device axis A1 and has a shape selected from circular, rectangular, hexagonal, octagonal, and decagonal, see also
[0081] Reference BA indicates a body axis. Such body axis may be configured at a length averaged distance to the external surface(s) of the luminescent material comprising element. In the cross-section (see dashed rectangle in
[0082] Referring to
[0083] Instead of a circular shape, the shape may also be rectangular, hexagonal, octagonal, or decagonal. Especially, the shape may be circular, hexagonal, octagonal, or decagonal. Even more especially circular (like a ring).
[0084] In embodiments, the luminescent material comprising element 100 may comprise a ceramic body comprising the luminescent material 110. In yet other embodiments, the luminescent material comprising element 100 may comprises a polymeric body 120 comprising the luminescent material 110 distributed in the polymeric body 120, wherein the polymeric body 120 comprises a polymeric material 125. The luminescent material 110 may be dispersed in the polymeric material 125. An embodiment is schematically depicted in
[0085] As schematically depicted in amongst others
[0086] As schematically depicted in
[0087] The luminescent material comprising element 100 may have a ring-shape. The luminescent material comprising element 100 may comprise a single luminescent material 110. However, the luminescent material comprising element 100 may also comprise a plurality of different luminescent material 110, which may optionally be configured separately. The ring-shaped luminescent material comprising element 100 (“phosphor ring”) may thus comprise a single luminescent material 110, see
[0088]
[0089] Amongst others, variants II and III allow at least 25%, such as at least about 50%, such as 50-75%, of the external surface of the luminescent material comprising element being in thermal contact with one or more of (a) the light transmissive element and (b) the optional thermally conductive element (see e.g.
[0090] As schematically depicted in the drawings, the device axis may be configured perpendicular to a plane parallel to the ring-shaped luminescent material comprising element.
[0091] Optionally, a dichroic coating is provided for higher collection efficiency of the converted light, as shown in
[0092] Embodiment I is also a transmissive mode embodiment, whereas embodiment II is a reflective mode embodiment.
[0093] In embodiment I, the (ring-shaped) luminescent material comprising element 100 protrudes from the light transmissive element 200. In embodiment II, the luminescent material comprising element 100 is configured in a cavity, which is shaped such that a (type) of parabolic reflector is created. The curvature may further assist in focusing. Reflection (especially back reflection of the luminescent material light 111), in both embodiments, may be reduced by a reflector 240. Especially the reflector 240 is transmissive for first light 11 but reflective for luminescent material light 111. Hence, the reflector 240 may be a dichroic reflector, like a dichroic coating.
[0094] In embodiments, the thermally conductive element 300 may be thermally coupled to a single face of the light transmissive element 200. Thermal coupling may be increase by increasing the contact surface. In embodiments, the thermally conductive element, such as a copper shaft (or shaft of other metal), may be extended or adapted as shown in
[0095]
[0096]
[0097] Hence, amongst others the invention provides a laser light engine comprising a rotating transparent rod with dome-shaped end cap through which blue laser light is focused onto a ring-shaped area of ceramic phosphor. The rod may be from sapphire. The phosphor ring may be sectorized, e.g. in RGBY. A dichroic coating may be provided to increase the efficiency. Further, the rod may be mounted on a shaft which is adapted to improve the thermal path. This may allow a high brightness light sources with good color quality, e.g. for use as retail spot, entertainment spot, narrow beam width spot, etc.
[0098] It seems that the heat spreading capacity is improved by pumping the phosphor in the indicated way through the dome-shaped cap. To prove this, a thermal simulation model was used. In these simulations the temperature distribution is calculated assuming a 30W thermal input distributed over the full ring-shaped phosphor. This corresponds to the heat that is generated when pumping a 1 mm.sup.2 spot with 100W of blue laser light. Due to the fast rotation of the rod this heat is spread out over the full phosphor ring. Cooling takes place by convection into the air and by conduction through the copper shaft. In the model it is not calculated what the temperature in the focused laser spot is, but what the quasi-stationary temperature distribution in the phosphor ring will be, i.e. of the phosphor that enters the laser spot by rotation of the rod. Two situations are compared: one where the blue laser light is incident through the sapphire rod, as intended (see e.g.
[0099] Architectures of laser-based light sources may comprise a blue pump laser and a ceramic phosphor (usually a YAG:Ce based) illuminated either in transmissive or reflective mode. All the phosphor converted laser-pumped sources are essentially Lambertian emitters, and brightness may especially be determined by the amount of emitted flux and the area of the source. In order to maximize the source brightness the area of the phosphor tend to be minimized and the directionality of pump laser light make it possible to deliver high pump power to these small phosphor area. Yet the factor which usually limits possibly achieved high brightness is a thermal quenching of a phosphor at high temperatures resulted from high power densities of the laser pump (usually in the range of 10-30 W/mm.sup.2 depending on the module and phosphor architecture). In a reflective or transmissive pumping architecture, the phosphor may have a compact regular shape (round, square, hexagonal shape) either embedded in a transparent material with high thermal conductivity or thermally attached to a metal heatsink with a highly reflective substrate. For the laser-based sources which require do deliver high luminous flux (in the range of 10 klm (kilo lumen) as e.g. for entertainment lighting fixtures) the phosphor size grows rapidly which can result in more problems with cooling and formation of hot-spots (in the center of a sample).
[0100] A comparison of phosphor samples performance of different size ranges used in a reflective mode and having similar thermal interface to a heatsink (silicone bond with optimized thickness of approx. few microns) was made. Results of thermo-optical tests with silicone bonded phosphor samples of different sizes at maximum temperature and onset of thermal quenching for 10 mm.sup.2 area samples were generated. The maximum power density realized was 18 W/mm.sup.2. Similarly, results were generated for a smaller phosphor of 0.5×0.5 mm.sup.2. The smaller phosphor sample allowed to reach pump power densities in the of order of >30 W/mm.sup.2 (with 0.5×0.5 mm2 samples), while for a large phosphor samples (10 mm.sup.2) thermal quenching effects manifest already at a level of 17 W/mm.sup.2 (all with silicone bonding to heatsink). Therefore for the sources where high flux and hence larger phosphor area is required alternative phosphor geometries resulting in better thermal management might be preferred.
[0101] Herein, alternative phosphor geometries for laser-based light sources are proposed which would allow for a better thermal management and finally higher brightness, compared to the regular shape top-emitting phosphor of the same area. It appeared to be possible to manage the light effectively from these alternative source shapes resulting in comparable collimated beam performance.
[0102] Amongst others, it is (again) referred to
[0103] Regular 2D-shapes of phosphor converters may be used for LEDs but also for laser-converted light sources. They may be compact and may allow an easy light management. An ideal starting situation for a light source for light manipulation/beam shaping may be a point source. Yet when higher flux output is required, the phosphor size may also grow, due to practical limitations of thermal interfaces to a heatsink and maximum laser pump power density on a phosphor. From a regular 2D-shape source the heat transfer to a heatsink goes in a phosphor plane (laterally) and directly to a heatsink. The lateral heat spreading appear to become less efficient for a larger converter sizes. Therefore, it may be beneficial to go from 2D-phosphor shapes to 1D-shapes which would make lateral heat transfer more efficient. Transforming a circle shape to a line shape can be an option, but efficient light management (e.g. making a narrow collimated beam of light) from a line source appears to be challenging. Closing a line source into a ring, thus making quasi 1D-phosphor ring shape (see amongst others variants II and III in
[0104] In the examples described herein and/or depicted, it appears that is possible to make comparable collimated beams starting from sources of different ring-shapes. Reflector optics combined with each source type were modelled in order to create a tight collimated beam. To have comparable results we chose to have equal emitting area of different source shapes of 10 mm.sup.2 and a maximum fixed reflector diameter of 50 mm.
[0105] As a reference situation we chose a top-emitting round phosphor of 10 mm.sup.2 area (03.57 mm). A side-emitting ring-phosphor of the same diameter 03.57 mm would have a width of a phosphor layer of 0.89 mm in order to have the same emitting area of 10 mm.sup.2. And a top emitting ring with 0.9 mm ring thickness would have inner and outer diameters of 6.6 mm and 7.5 mm respectively. A reference source combined with parabolic reflector of 26.2 mm height above the source results in a collimated beam of 5.6° FWHM with a center beam power of 52.1 cd/lm. The height of the reflector determines the beam width and the amount of uncontrolled spill light, not interacting with the reflector walls. We have chosen here a reflector height of 26.2 mm (from the source) as a reference situation.
[0106] An alternative shape of a phosphor converter is a ring-shape, where a phosphor width is much smaller than its length along the circumference. An example of such an architecture is shown in
[0107] Hence, in embodiments (see e.g.
[0108]
[0109]
[0110]
[0111]
[0112]
[0113] The invention can be applied in the applications where high source brightness is required, e.g. in retail and hospitality lighting, entertainment lighting. Amongst others, the invention may provide a static laser-pumped phosphor configuration where phosphor has quasi-1D dimensionality (ring-shape phosphor where it's dimension in one direction (width) is much smaller than dimension in the other direction (length or circumference)). In embodiments, a shape of circumference is a circle, (a square), a hexagon, etc. In embodiments, a phosphor is attached on a transparent optical material with good heat conductivity (e.g. sapphire) or non-transparent heatsink (e.g. copper or ceramics or a combination). Yet further, in embodiments a dominant direction of phosphor emission is perpendicular to the plane of the phosphor shape (e.g. top-emitting ring) or in plane of the phosphor shape (side emitting ring).
[0114] Referring to
[0115] The term “plurality” refers to two or more.
[0116] The terms “substantially” or “essentially” herein, and similar terms, will be understood by the person skilled in the art. The terms “substantially” or “essentially” may also include embodiments with “entirely”, “completely”, “all”, etc. Hence, in embodiments the adjective substantially or essentially may also be removed. Where applicable, the term “substantially” or the term “essentially” may also relate to 90% or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%.
[0117] The term “comprise” includes also embodiments wherein the term “comprises” means “consists of”.
[0118] The term “and/or” especially relates to one or more of the items mentioned before and after “and/or”. For instance, a phrase “item 1 and/or item 2” and similar phrases may relate to one or more of item 1 and item 2. The term “comprising” may in an embodiment refer to “consisting of” but may in another embodiment also refer to “containing at least the defined species and optionally one or more other species”.
[0119] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.
[0120] The devices, apparatus, or systems may herein amongst others be described during operation. As will be clear to the person skilled in the art, the invention is not limited to methods of operation, or devices, apparatus, or systems in operation.
[0121] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims.
[0122] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim.
[0123] Use of the verb “to comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.
[0124] The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements.
[0125] The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In a device claim, or an apparatus claim, or a system claim, enumerating several means, several of these means may be embodied by one and the same item of hardware. 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.
[0126] The invention also provides a control system that may control the device, apparatus, or system, or that may execute the herein described method or process. Yet further, the invention also provides a computer program product, when running on a computer which is functionally coupled to or comprised by the device, apparatus, or system, controls one or more controllable elements of such device, apparatus, or system.
[0127] The invention further applies to a device, apparatus, or system comprising one or more of the characterizing features described in the description and/or shown in the attached drawings. The invention further pertains to a method or process comprising one or more of the characterizing features described in the description and/or shown in the attached drawings.
[0128] The various aspects discussed in this patent can be combined in order to provide additional advantages. Further, the person skilled in the art will understand that embodiments can be combined, and that also more than two embodiments can be combined. Furthermore, some of the features can form the basis for one or more divisional applications.