Luminescent Layer Protected by Low Oxygen Transmission Polymer Foils
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Solution Overview
Problem
Luminescent materials, particularly organic phosphors and quantum dots, are prone to deterioration when exposed to oxygen, leading to a short lifespan in lighting applications, and existing protection methods using glass and hermetic sealing are costly and inflexible.
Innovation Solution
A stack of layers comprising a luminescent layer sandwiched between two outer layers made of light-transmitting polymeric materials with low oxygen transmission rates, providing a cost-effective and flexible solution to protect luminescent materials from environmental oxygen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass plates with hermetic sealing are used to protect organic phosphors, then protection against oxygen is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive glass plates with inexpensive polymer foil layers that provide sufficient oxygen protection. The polymer layers are much cheaper to manufacture and process than glass, eliminating the need for costly hermetic sealing operations while maintaining adequate protection for the luminescent material.
Solution Approach 2:
The patent uses flexible polymer foil layers instead of rigid glass plates. These thin polymer films can be easily laminated to the luminescent material and provide effective oxygen barrier properties. The flexibility allows for easier manufacturing and various application configurations compared to rigid glass assemblies.
2Reliability
If glass plates are used to protect luminescent material, then protection against oxygen is improved, but flexibility is reduced
Solution Approach 1:
The patent employs flexible polymer foil layers that can be conformally applied to various surfaces and configurations. These polymer films maintain their flexibility allowing the luminescent material to be used in bent or irregular shapes, unlike rigid glass plates that would break or require complex mounting structures.
Solution Approach 2:
The patent creates a composite structure by laminating polymer foil layers with the luminescent material. This composite approach combines the protective barrier properties of the polymer with the optical properties of the luminescent material, resulting in a flexible, integrated assembly that maintains both protection and adaptability.
3Reliability
If hermetic sealing is applied to glass plates, then protection against oxygen is improved, but device complexity increases
Solution Approach 1:
The patent eliminates complex hermetic sealing structures by using inexpensive polymer foil layers that provide inherent barrier properties. The polymer layers are simply laminated to the luminescent material without requiring additional sealing components, adhesives, or assembly steps, greatly simplifying the overall device structure.
Solution Approach 2:
The flexible polymer foil layers can be directly laminated to the luminescent material surface, creating a simple integrated structure. This approach eliminates the need for rigid glass assemblies with complex sealing joints, gaskets, or mounting hardware, resulting in a much simpler device architecture.
4Reliability
If polymer layers with low oxygen transmission rate are used, then protection against oxygen is improved, but light transmission may be affected
Solution Approach 1:
The patent uses thin polymer foil layers that provide effective oxygen barrier properties while maintaining high light transmission. The thinness of the polymer films minimizes light absorption and scattering, allowing most light to pass through while still providing adequate protection against oxygen degradation of the luminescent material.
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 significantly extends the lifespan of luminescent materials by reducing oxygen exposure, offering a cost-effective and flexible protection method suitable for various lighting applications, including lamps and luminaires.
Implementation Method 1
the luminescent material is configured to absorb light according to an absorption spectrum and to convert a portion of the absorbed light towards light of a light emission spectrum
Implementation Method 2
The first outer layer and the second outer layer are of a light transmitting polymeric material and have an oxygen transmission rate lower than 30 cm3/m2/24h/0.2MPa
Data Source
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AI summary
A stack of layers 102, a lamp, a luminaire and a method of manufacturing a stack of layers is disclosed. The stack of layers 102 comprises a first outer layer 102, a second outer layer 106 and a luminescent layer 104. The first outer layer 102 and the second outer layer 106 are of a light transmitting polymeric material and have an oxygen transmission rate lower than 30 cm3/(m2·day) measured under standard temperature and pressure (STP). The luminescent layer 104 is sandwiched between the first outer layer 102 and the second outer layer 106 and comprises a light transmitting matrix polymer and a luminescent material 108 being configured to absorb light according to an absorption spectrum and convert a portion of the absorbed light towards light of a light emission spectrum.