Remote Luminaire Screen for Moisture-Protected Phosphor Conversion
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Solution Overview
Problem
Existing LED-based lamps face challenges in using sensitive phosphors, particularly those sensitive to moisture, in maintaining brightness and light distribution, and in achieving efficient and uniform light output while protecting the phosphors from moisture and chemical attacks.
Innovation Solution
A remote luminaire design with a screen comprising at least three layers, where a color conversion phosphor layer is sandwiched between two protective layers of plastic or glass, and includes light-scattering particles to enhance light distribution and protect the phosphors from moisture, allowing for the use of sensitive phosphors and reducing thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If phosphors sensitive to moisture are used to achieve efficient color conversion, then the light output and efficiency are improved, but the phosphors deteriorate due to moisture exposure
Solution Approach 1:
A hermetic seal structure acts as an intermediary barrier between the phosphor layer and the moisture-containing environment. The seal includes a sealing surface on the housing and a corresponding sealing element that creates a protected microenvironment, allowing sensitive phosphors to function efficiently without direct moisture exposure.
Solution Approach 2:
The patent creates a protected inert environment around the phosphor layer by sealing it within a housing structure that excludes moisture and air. This hermetic enclosure maintains stable conditions for the phosphors, preventing degradation while allowing them to convert light efficiently.
2Loss of energy
If phosphors are placed close to the LED for efficient color conversion, then energy efficiency is improved, but thermal stress and moisture exposure reduce phosphor lifespan
Solution Approach 1:
The hermetic seal serves as a protective intermediary that allows the phosphor to be positioned close to the LED for efficient energy conversion while simultaneously shielding it from thermal and moisture stress that would otherwise reduce its lifespan.
Solution Approach 2:
By enclosing the phosphor in a sealed, moisture-free environment, the patent enables close proximity to the LED for efficient color conversion while protecting the phosphor from degrading thermal and environmental conditions that would limit its operational duration.
3Ease of manufacture
If a simple single-layer phosphor structure is used, then manufacturing is easier, but light distribution uniformity and brightness are insufficient
Solution Approach 1:
The patent segments the phosphor conversion function into multiple layers with different phosphor materials, each responsible for converting specific wavelengths. This segmentation allows for improved light distribution uniformity and enhanced brightness while maintaining manufacturing feasibility through modular assembly.
Solution Approach 2:
The patent employs composite material structures combining different phosphor types in layered configurations. This composite approach optimizes light absorption and emission characteristics, achieving superior brightness uniformity and distribution while remaining manufacturable through established material combination techniques.
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 increases the luminaire's efficiency and brightness, maintains phosphor quality, and allows for the use of sensitive phosphors in damp environments, reducing heat-related losses and extending the lifespan of the luminaire.
Implementation Method 1
These materials absorb at least part of the light emitted by an LED chip and emit light in a different wavelength
Implementation Method 2
The absorbed light is then emitted again by the phosphor in a different wavelength
Implementation Method 3
the color conversion layer in addition to the at least one color conversion phosphor contains light-scattering particles
Implementation Method 4
the first layer has a coating with which the light of the first wavelength and the light of the second wavelength, which is backscattered by the color conversion layer, is reflected again
Data Source
Figure 1~2
AI summary
The lamp has an LED (16) that is arranged at specific distance from a screen (20) so that light from the LED falls on an inner side of screen. A light transmission layer (S1) of screen is set for transmitting light of first wavelength (L1). A color conversion layer (S2) is made of color-converting phosphor material and support material. A light transmission layer (S3) is set for transmitting light of first wavelength and second wavelength (L2) which is larger than first wavelength. The light transmission layers are made of plastic or glass material.