Color Converting Element With Segmented Wavelength Cells
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Solution Overview
Problem
Conventional white light emitting diodes (LEDs) face efficiency and brightness deterioration due to interactions between color converting phosphors, and struggle with color rendering and spectral characteristics, especially in high-power applications where phosphor materials are prone to degradation and reabsorption issues.
Innovation Solution
A color converting element using glass or crystallized glass materials with ceramic phosphors or active ions, arranged in specific patterns like stripes or lattices, to minimize interactions and enhance thermal and chemical durability, allowing for improved color rendering and spectral characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phosphors are dispersed in resin or silicone resin, then the color converting element can be easily manufactured, but efficiency and brightness deteriorate due to interactions between phosphors
Solution Approach 1:
The patent divides the color converting element into multiple separate wavelength conversion cells (first, second, and third cells) containing different phosphors. These cells are arranged in a layered structure with resin layers between them, physically separating the phosphors to minimize interactions while maintaining ease of manufacture through a systematic assembly process.
Solution Approach 2:
The patent transitions from a two-dimensional planar arrangement of phosphors to a three-dimensional layered structure with wavelength conversion cells stacked vertically. This dimensional change allows phosphors to be separated in the vertical dimension while maintaining horizontal coverage, reducing interactions without compromising manufacturing efficiency.
2Illumination intensity
If multiple phosphors are mixed together, then color rendering characteristics can be improved, but reabsorption issues and brightness deterioration occur
Solution Approach 1:
The patent segments different phosphors into separate wavelength conversion cells arranged in layers. Each cell contains specific phosphors (e.g., yellow phosphor in first cell, red phosphor in second cell) separated by resin layers, allowing good color rendering through multiple phosphors while minimizing reabsorption by preventing direct interaction between them.
Solution Approach 2:
The patent introduces resin layers as intermediary materials between wavelength conversion cells containing different phosphors. These resin layers act as barriers that prevent direct contact between phosphors, eliminating reabsorption issues while allowing the system to benefit from multiple phosphors for improved color rendering.
3Ease of manufacture
If phosphor particle size is increased, then manufacturing process is simplified, but interaction between phosphors increases causing efficiency loss
Solution Approach 1:
The patent segments phosphors into separate wavelength conversion cells with resin layers between them. This allows the use of larger phosphor particles within each cell for manufacturing simplicity while the physical separation prevents interactions that would cause efficiency loss, resolving the contradiction between particle size and interaction effects.
4Area of stationary object
If color converting elements are placed closer together, then device size is reduced, but interaction between elements increases causing brightness deterioration
Solution Approach 1:
The patent arranges wavelength conversion cells in a vertical layered structure rather than spreading them horizontally. This dimensional reorganization allows the device to maintain a compact footprint while separating phosphors in the vertical dimension through resin layers, preventing interactions that would reduce brightness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively minimizes efficiency and brightness deterioration, enhances thermal and chemical durability, and facilitates easy adjustment of color rendering characteristics in high-power white LEDs by using glass materials with ceramic phosphors or active ions, arranged in specific patterns to reduce reabsorption and interaction issues.
Implementation Method 1
a color converting element which absorbs blue light emitted from the blue LED and emits white light through luminescence of yellow or green light and red light
Implementation Method 2
the glass-containing material includes a ceramic phosphor-containing glass or crystallized glass material, or an active ion for color conversion
Data Source
AI summary
Disclosed are a color converting element and a method for manufacturing the color converting element. The disclosed color converting element includes: first wavelength conversion cells spaced apart from one another; and second wavelength conversion cells arranged among the first wavelength conversion cells. The first and second wavelength conversion cells are made of a material containing glass. The color converting element of the disclosed technology is configured in that color converting cells having different color converting characteristics are periodically arranged, when the color converting element is applied to a color converting glass material which may improve thermal and chemical durability of white LEDs, thus minimizing the degradation of efficiency or luminance caused by an interaction between color converting phosphors or active ions and allowing for ease of adjustment of color rendering index.