Hollow Cylindrical Wavelength Conversion Components for Omnidirectional LED Lamps
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Solution Overview
Problem
LED-based lamps face challenges in matching the omnidirectional emission characteristics of incandescent bulbs due to directional light emission and have high manufacturing costs associated with photoluminescence wavelength conversion components, which are typically made by expensive injection molding.
Innovation Solution
The development of photoluminescence wavelength conversion components with a hollow cylindrical design and a high aspect ratio, manufactured using extrusion methods, which allows for cost-effective production and improved emission patterns, including omnidirectional emission, by distributing phosphor materials homogeneously throughout the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photoluminescence wavelength conversion components are manufactured using injection molding, then manufacturing precision can be achieved, but manufacturing cost increases significantly
Solution Approach 1:
The patent applies this principle by replacing expensive injection molded components with cheaper extruded alternatives. The extrusion process uses simpler tooling and materials that can be readily discarded or replaced, eliminating the need for costly injection molding equipment and complex molds while maintaining adequate component precision for the application.
Solution Approach 2:
The patent changes the manufacturing process parameters from injection molding to extrusion. This parameter change fundamentally alters the production method, reducing equipment complexity and cost while achieving the necessary component specifications through a more economical process that is better suited for the required precision level.
2Use of energy by moving object
If LEDs are used to generate white light, then energy efficiency and operating lifetime are improved, but omnidirectional emission characteristics are lost
Solution Approach 1:
The patent segments the light emission function by separating the LED light source from the wavelength conversion function. Multiple LEDs can be arranged in specific patterns, and the photoluminescence component converts their combined output into omnidirectional white light, achieving both energy efficiency and desired emission characteristics through functional segmentation.
Solution Approach 2:
The patent transitions from the inherently directional emission of individual LEDs to omnidirectional emission by introducing a photoluminescence wavelength conversion component. This adds a spatial dimension to the light distribution, transforming the concentrated directional output into radially distributed white light that mimics traditional bulb characteristics.
3Device complexity
If phosphor material is mixed with light transmissive material and applied directly to LED die, then manufacturing simplicity is achieved, but thermal degradation of phosphor occurs
Solution Approach 1:
The patent extracts the phosphor material from direct contact with the LED die by implementing a remote phosphor configuration. The photoluminescence wavelength conversion component is positioned at a distance from the heat source, separating the phosphor from the thermal environment while maintaining the optical coupling necessary for wavelength conversion. This extraction eliminates thermal degradation while preserving manufacturing efficiency.
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 enhances light emission efficiency and distribution, reducing re-absorption of light and mimicking the filament light emission of incandescent bulbs, while lowering manufacturing costs through more affordable production methods.
Implementation Method 1
white LEDs include one or more phosphor materials, that is photoluminescence materials, which absorb a portion of the radiation emitted by the LED and re-emit radiation of a different color (wavelength)
Implementation Method 2
configured to enclose the LED(s) and provide for omnidirectional emission of light from the lamp
Data Source
AI summary
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.