Phosphor Layer on Optical Component for LED Color Uniformity
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Solution Overview
Problem
High-intensity LEDs face issues with temperature-dependent light characteristics and thermal degradation of phosphor materials, leading to non-uniform color emission and complex fabrication processes due to phosphor distribution within encapsulation materials.
Innovation Solution
Applying a substantially uniform thickness layer of phosphor on the surface of an optical component, such as a lens, which can be made of plastics or glass, to absorb and emit radiation, thereby reducing manufacturing steps and ensuring uniform color output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphor is distributed within encapsulation materials, then light emission is achieved, but color uniformity deteriorates and fabrication complexity increases
Solution Approach 1:
The patent extracts the phosphor from the encapsulation material and places it on the optical component surface instead. This separation allows the phosphor to be applied as a distinct layer that can be precisely controlled for uniform thickness, thereby improving color uniformity while simplifying the fabrication process by eliminating the need to mix phosphor within the encapsulation material.
Solution Approach 2:
The patent transitions the phosphor from a three-dimensional distribution within the encapsulation material to a two-dimensional layer on the optical component surface. This dimensional change enables better control over phosphor distribution and thickness uniformity, leading to improved color consistency and simplified application processes.
2Productivity
If phosphor is distributed within encapsulation materials, then light emission is achieved, but manufacturing steps increase
Solution Approach 1:
The patent combines the phosphor application step with the optical component assembly process. By applying phosphor directly to the optical component surface before or during assembly, the manufacturing process is streamlined, reducing the total number of discrete steps required compared to separately mixing phosphor into encapsulation materials and then assembling.
Solution Approach 2:
The patent applies the phosphor to the optical component surface in advance, before final assembly. This preliminary action allows for optimized phosphor placement and uniformity control, and eliminates the need for subsequent phosphor mixing or adjustment steps during assembly, thereby improving manufacturing efficiency.
3Power
If high intensity LEDs are used, then light output is increased, but thermal degradation of phosphor occurs
Solution Approach 1:
The patent introduces the optical component as an intermediary between the high-intensity LED and the phosphor. This optical component acts as a thermal barrier and heat sink, absorbing and dissipating heat away from the phosphor layer, thereby protecting the phosphor from thermal degradation while allowing the LED to operate at high intensity.
Solution Approach 2:
The patent positions the phosphor on the optical component surface where it is protected from direct thermal exposure before thermal damage can occur. The optical component serves as a pre-positioned thermal buffer that cushions the phosphor against the high temperatures generated by intense LED operation, preventing degradation in advance.
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
This approach results in a more uniform color emission and reduced manufacturing costs by simplifying the fabrication process, while providing direct color conversion and environmental protection for the phosphor.
Implementation Method 1
a phosphor configured to absorb at least a portion of said first wavelength range radiation and emit radiation having a second wavelength range
Data Source
AI summary
A method of manufacturing an LED lighting arrangement, comprises: receiving an optical component having a diffusing material that is light diffusive and at least one photoluminescent material that is excitable by light of a first wavelength range and which emits light of a second wavelength range; receiving an LED assembly that is operable to generate the light of the first wavelength range and mounting the optical component to the LED assembly to form the LED lighting arrangement. The optical component having the diffusing and photoluminescent materials is mass produced separately from the LED assembly and can be selected such that light generated by the optical component combined with the light generated by the LED assembly corresponds to light of a selected color. Also disclosed are LED lighting arrangements, components for LED lighting arrangements and methods of fabricating an optical component.