Reduced Phosphor Lighting Devices via Spatial Separation
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Solution Overview
Problem
Conventional LED lighting devices require a high amount of phosphor material, which increases production costs and can result in phosphor waste during manufacturing, while also compromising color uniformity and efficiency.
Innovation Solution
A lighting device with a reduced phosphor content is achieved by spatially separating the phosphor from the LED light source and integrating it into a diffuser structure, which includes a reflective material to maintain color uniformity and efficiency, using a diffuser constructed from materials like silicones, polyesters, and polycarbonates, and applying the phosphor in a thin or dilute layer to reduce the total amount of phosphor required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If phosphor is deposited directly on the LED light source in conventional devices, then sufficient wavelength conversion is achieved, but phosphor usage increases by up to 60% and color uniformity deteriorates
Solution Approach 1:
The device separates the phosphor deposition location from the LED chip surface. Instead of coating phosphor directly on the LED, the patent applies phosphor to a separate substrate or housing surface, dividing the wavelength conversion function from the light generation function. This segmentation reduces phosphor waste and improves color uniformity by allowing better control of phosphor distribution.
Solution Approach 2:
The patent introduces an intermediary substrate or housing surface between the LED light source and the phosphor material. This intermediary element serves as a controlled platform for phosphor application, enabling precise phosphor placement and reducing direct contact between phosphor and LED chip, thereby minimizing phosphor waste and improving color consistency.
2Reliability
If high amounts of phosphor are used in conventional LED devices, then wavelength conversion is sufficient, but production costs increase due to material waste
Solution Approach 1:
The patent extracts the phosphor material from direct contact with the LED chip and relocates it to a separate substrate or housing surface. This extraction allows for more efficient phosphor utilization by preventing phosphor loss during LED assembly and reducing the total amount of phosphor needed to achieve the same wavelength conversion efficiency, thereby lowering production costs.
Solution Approach 2:
The patent changes the physical parameters of phosphor application by transitioning from direct LED chip coating to substrate-based phosphor deposition. This parameter change includes modifying phosphor layer thickness, distribution density, and application method, which collectively reduce phosphor consumption while maintaining wavelength conversion efficiency and reducing material waste.
3Illumination intensity
If phosphor is applied in thick layers to ensure color quality, then wavelength conversion is adequate, but phosphor waste increases during manufacturing
Solution Approach 1:
The patent applies phosphor locally on the substrate or housing surface rather than in thick uniform layers on the LED chip. This local quality approach allows precise control of phosphor placement in areas where wavelength conversion is actually needed, reducing unnecessary phosphor material and minimizing waste during manufacturing while maintaining adequate color quality.
Solution Approach 2:
The patent uses partial phosphor coverage on the substrate surface instead of applying excessive phosphor layers. By strategically placing phosphor only where required for wavelength conversion and using thinner, more controlled layers, the patent achieves sufficient color quality with reduced phosphor consumption and minimized manufacturing waste.
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 reduces the total phosphor usage by up to 60% compared to conventional devices, while maintaining spatially correlated color temperature variance and angular color homogeneity, thereby lowering production costs and enhancing color uniformity and efficiency.
Implementation Method 1
an LED can be coated or covered with a phosphor layer having a phosphor material that absorbs radiation energy in one portion of the electromagnetic spectrum and emits energy in another portion of the electromagnetic spectrum
Implementation Method 2
a diffuser structure configured for color mixing of the light from the solid-state light source
Data Source
AI summary
A lighting device comprising a solid-state light source, and a diffuser configured for color mixing of the light from the solid-state light source and spatially separated therefrom, the diffuser comprising at least one phosphor material. Methods of fabricating a lighting device having a reduced total amount of phosphor comprising combining an amount of phosphor with a diffuser structure.