TW201236214A - LED-based illumination modules with thin color converting layers - Google Patents

Abstract

An illumination module includes a plurality of Light Emitting Diodes (LEDs). The illumination module may include a reflective color converting element with a PTFE layer and a color converting layer fixed to the PTFE layer. The color converting layer includes phosphor particles embedded in a polymer matrix and has a thickness that is less than five times an average diameter of the phosphor particles. The illumination module may include a transmissive color converting element. The color converting elements may be produced by mixing a polymer binder with a solvent and phosphor particles to form a homogeneous suspension of the phosphor particles. The homogeneous suspension is applied to a surface to form an uncured color converting layer, which is heated to vaporize the solvent. The cured color converting layer includes the phosphor particles suspended in the polymer binder.

Description

201236214 VI. Description of the Invention: [Technical Field of the Invention] The illustrated embodiment relates to an illumination module including a light-emitting diode (LED). The present application is based on the priority of US Provisional Application No. 61/428,691, filed on Dec. 30, 201, the entire disclosure of which is hereby incorporated by reference. [Prior Art] Due to the limitation of the light output level or flux generated by the illumination device, the use of the light-emitting diode in general illumination is still limited. Illumination devices that use LEDs also typically suffer from poor color quality with features of color point instability. This color point instability varies over time and from part to time. Poor color quality is also characterized by poor color rendering due to the spectrum produced by the LED source with or without power. In addition, illumination devices that use LEDs typically have spatial variations in color and/or angular variations. In addition, due to the need for the required color control electronics and/or sensors to maintain the color point of the source, or only a small portion of the led produced to meet the color and/or flux requirements of the application Therefore, lighting devices using LEDs are more expensive. Therefore, improvement of an illumination device using a light-emitting diode as a light source is desired. SUMMARY OF THE INVENTION A lighting module includes a plurality of light emitting diodes (LEDs). The illumination module can include a reflective color conversion element having a PTFE layer and a layer of color conversion 161207.doc 201236214 fixed to the PTFE layer. The color conversion layer comprises phosphor particles embedded in a polymer matrix and has a thickness that is less than one-fifth the average diameter of one of the phosphor particles. The lighting module can include a transmissive color conversion element. The color conversion elements can be produced by mixing a polymer binder with a solvent and phosphor particles to form a homogeneous suspension of the phosphor particles. The homogeneous suspension is applied to a surface to form an uncured color conversion layer, and the uncured color conversion layer is heated to evaporate the solvent. The cured color conversion layer comprises the phosphor particles suspended in the polymer binder. In one embodiment, an apparatus includes a light source subassembly having a plurality of light emitting diodes (LEDs); and a a reflective color conversion element comprising a polytetrafluoroethylene (PTFE) layer and a first color conversion layer fixed to the PTFE layer, wherein the first color conversion layer comprises a plurality of first embedded in a polymer matrix A type of phosphor particle, and wherein one of the first color conversion layers has a thickness that is less than five times the average diameter of one of the %·filler particles. In one embodiment, a device includes a light source subassembly having a plurality of light emitting diodes (LEDs); a reflective color conversion element comprising a layer of polytetrafluoroethylene (PTFE) and being affixed to the PTFE layer a first color conversion layer, wherein the first color conversion layer comprises a plurality of first type of scale particles embedded in a polymer matrix and wherein one of the first color conversion layers has a thickness smaller than the And a transmission color conversion element comprising an optically transparent layer and a second color conversion layer fixed to the optically transparent layer, wherein the second color conversion layer 161207.doc 201236214 A plurality of second-disc photo-particles of the package 3 wherein the second such filler particles have a peak emission wavelength of no more than 600 nm. In one embodiment, a device includes a plurality of light emitting diodes (LEDs); a transmissive color conversion assembly positioned to receive light from the plurality of emitted light, the transmitted color conversion assembly comprising: a first a transmissive optical element, a second transmissive optical element; a first color conversion material disposed thereon. Between the first transmissive optical element and the second transmissive optical element; and a: a sealing material disposed between the first transmissive optical element and the second transmissive optical element, which fixedly the first transmissive optical An element is coupled to the first transmissive optical element, wherein the first color conversion material is comprised by the first transmissive photonic element and the second transmissive optical element and the sealing material. In an embodiment, a method comprises mixing a polymer binder with a solvent and a plurality of disc particles to form a homogenous 愍' pre-liquid of the scalar particles, and applying the homogeneous suspension to the solution. Forming an uncured color conversion layer, and heating the uncured color conversion layer to evaporate the solvent to form a cured color conversion layer, wherein the cured color conversion layer comprises a suspension of the polymer binder What are these scales in the body? And wherein the thickness of one of the cured color conversion layers is less than five times the average diameter of one of the phosphor particles. Further details and embodiments and techniques are set forth in the following embodiments. The present invention is not defined in this month. The invention is defined by the scope of the patent application. [Embodiment] Reference will now be made in detail to the prior art examples and certain embodiments of the present invention, 161 207. doc. 6 - 201236214 Examples of the invention are illustrated in the accompanying drawings. 1, 2 and 3 illustrate three exemplary lighting fixtures, all labeled 150. The lighting fixture illustrated in (5) comprises a lighting module 丨00 having a rectangular outer dimension. The lighting fixture illustrated in Figure 2 comprises an illumination die (10) having a -round appearance dimension. The lighting fixture illustrated in Figure 3 includes a lighting module integrated into a retrofit lamp unit. These examples are for illustrative purposes. Examples of lighting modules of a generally polygonal shape and an elliptical shape are also contemplated. The lighting fixture 15 includes a lighting module 100, a reflector 140, and a luminaire 130. As shown, the luminaire 13 〇 includes a heat sink capability. However, luminaire 130 can include other structures and mounting components (not shown). Reflector 140 is mounted to illumination module 100 to collimate or deflect light emitted from illumination module 1 (10). The reflector 14 can be made of a conductive material, such as a material comprising one or a piece of copper, and can be thermally coupled to the illumination module 100. The heat flows through the conduction through the illumination module 1 and the thermally conductive reflector 丨4〇. Heat also flows through the heat convection above the reflector 140. Reflector 140 can be a compound parabolic focus, wherein the focus is constructed of or coated with a highly reflective material. The optical component (such as a diffuser or reflector 140) can be removably consuming to the illustrated module (10), for example, by means of a thread, a clamp, a twist-lock mechanism, or other suitable configuration. As illustrated in FIG. 3 (4), the anti-soil cloth has, for example, a wavelength conversion material, a diffusing material or a side wall 141 of a desired material and a window 142. The listening period is as shown in FIG. 1, FIG. 2 and FIG. The lighting module 1 is mounted to the heat sink 130. The heat sink 130 can be made of a thermally conductive material such as one of aluminum or steel I61207.doc 201236214 and can be thermally coupled to the lighting module 100. The heat flows through the conduction through the illumination module 100 and the heat dissipation fins 13Q. Theample also flows through the heat convection on the heat sink 130. The illumination module 100 can be used to clamp the illumination module 100 to the heat sink. The 13G thread is attached to the heat sink 130. To facilitate the removal and replacement of the lighting module 丨00, the lighting module 丨00 can be, for example, by a clamp mechanism, a twist-lock mechanism, or other suitable configuration. The removal method is consuming to the heat sink 130. The lighting module 100 includes, for example, at least one thermally conductive surface that is thermally coupled to the heat sink 130, either directly or using thermal grease, thermal tape, thermal pad or thermal epoxy. Cool the LED and flow to the watt of each LED on the board A thermal contact area of at least 5 square millimeters (but preferably 100 square millimeters) should be used. For example, in the case of using one LED, a heat sink contact area of 1000 to 2000 square millimeters should be used. A larger heat sink 13 准许 permits the LEDs 102 to be driven at a higher power, and also allows for different heat sink designs. For example, some designs may exhibit cooling capabilities that are less dependent on the orientation of the heat sink. The device may be thermally removed using a fan or other solution for forced cooling. The bottom fin may include an aperture to enable electrical connection to the lighting module 100. Figure 4 illustrates by way of example An exploded view of the components of the LED-based lighting module 100 illustrated in Figure i. It should be understood that, as used herein, an LED-based lighting module is not a LED but an LED. A light source or luminaire, or an LED light source or a component part of a luminaire. For example, an LED-based lighting module can be an LED-based backup lamp such as that depicted in Figure 3. Based on Led It Ming module 1〇〇161207.doc 201236214 includes one or more LED dies or packaged LEDs and LED dies or packaged LEDs attached to one of the mounting boards. In one embodiment, the LEDs 102 are packaged LEDs such as Luxeon Rebel manufactured by philips Lumileds Lighting. Other types of packaged LEDs can also be used, such as OSRAM (Oslon package), Luminus device (USA), Cree (USA), Nichia (曰本), Or their packaged LEDs manufactured by Tridonic (Austria). As defined herein, a packaged LED is an assembly of one or more LED dies that contain electrical connections (such as wire bond connections or stud bumps) and may include an optical component and thermal, mechanical, and The dielectric ^ led wafer typically has a size of about 1 mm X 1 mm X 0.5 mm, but these dimensions can vary. In some embodiments the 'LED 102' can comprise a plurality of wafers. The plurality of wafers can emit light of similar or different colors (e.g., red, green, and blue). Mounting plate 104 is attached to mounting base 110 and secured in place by mounting plate retaining ring 103. At the same time, the mounting plate filled with the LED 1〇2 and the mounting plate clamping ring 1 〇3 constitute the light source sub-assembly 丨丨5. The light source subassembly j 15 is operable to convert electrical energy into light using the LEDs 102. The light emitted from the light source sub-assembly U 5 is directed to the light conversion sub-assembly [丨6 for color mixing and color shirt conversion. The light conversion sub-assembly 116 includes a cavity 1〇5 and an output port, which is illustrated as, but not limited to, an output window 1〇8. The light converter subassembly 116 optionally includes either or both of the bottom reflector insert 1〇6 and the sidewall insert丨〇7. The output window 1〇8 (if used as an output port) is fixed to the top of the cavity 1〇5. In some embodiments, the output window 108 can be secured to the cavity 105 by an adhesive. To promote heat dissipation from the output window to cavity 1 () 5, a thermally conductive adhesive is desirable. The adhesive should be reliably resistant to the temperature present at the interface between the wheel window 108 and the cavity 105 161207.doc 201236214. Moreover, preferably, the adhesive reflects or transmits as much incident light as possible, rather than absorbing light emitted from the output window 108. In one example, heat resistance, thermal conductivity, and optics of one of several adhesives manufactured by Dow Corning (USA) (eg, Dow Corning SE4420, SE4422, SE4486, Ι-ογ), or SE9210 model) The combination of properties provides the right performance. However, other thermal adhesives can also be considered. The inner sidewall of the cavity 105 or sidewall insert 1 〇 7 (when placed inside the cavity ι 5 as appropriate) is reflected such that light from the LED 102 and any wavelength converted light are within the cavity 109 The reflection is transmitted through the output window when the output port (eg, output window 108) is mounted over the light source subassembly 115. The bottom reflector insert 106 can be placed over the mounting plate 1 〇4 as appropriate. The bottom reflector insert 106 includes a plurality of apertures such that the illuminated portion of each LED 102 is not obscured by the bottom reflector 1 〇 6. The sidewall entrapment 1 〇 7 can be placed inside the cavity 105 as such such that when the cavity 105 is mounted over the light source subassembly U5, the interior surface of the sidewall insert 107 directs light from the LED 102 to the output window. Although the inner side walls of the cavity 1〇5 are rectangular in shape as viewed from the top of the illumination module 1〇〇, other shapes (e.g., clover shapes or polygons) are contemplated. In addition, the inner side wall of the cavity 1〇5 can be tapered or curved outward from the mounting plate 1〇4 to the output window 108 instead of being perpendicular to the output window 108 as shown in the bottom reflector insert 106 and sidewall embedded The member 1〇7 can be highly reflective such that the light reflected downward in the cavity 109 is typically reflected toward the output port (eg, the output window. Additionally, the inserts 1〇6 and 107 can have a high thermal conductivity such that 161207. Doc •10-

201236214 Extra radiator. By way of example, the inserts 1〇6 and ι7 can be made by means of a highly thermally conductive material such as a material based on the name which is treated to render the material highly reflective and durable. By way of example, a material called Mir(R) 8 made by Alanod (-Germany) can be used. High reflectivity can be achieved by polishing the aluminum or by covering the inner surfaces of the inserts 106 and 1 by means of one or more reflective coatings. Another option is the insert

106 and 107 may be made of a highly reflective thin material such as VikuitiTM ESR sold by 3M (USA), Lumirr〇rTM E60L manufactured by Toray (Japan), or such as by Furukawa (10) Coffee Co., Ltd. ( It is made of microcrystalline polyethylene terephthalate (MCPET) manufactured by 曰本). In other examples, the inserts 106 and 107 can be made of a polytetrafluoroethylene (pTFE) material. In some instances, inserts 106 and 107 can be made from one of the PTFE materials sold by W.l. Gore (USA) and Berghof (Germany) to one millimeter thick. In still other embodiments, the inserts 106 and 107 can be constructed from a PTFE material (such as ESR, E60L, or MCPET) lined with a thin reflective layer such as a metal layer or a non-metallic layer. Additionally, a highly diffuse reflective coating can be applied to either of the sidewall insert 107, the bottom reflector insert 106, the output window 〇8, the cavity 105, and the mounting plate 104. These coatings may comprise titanium dioxide (Ti〇2), zinc oxide (ZnO) and barium sulfate (BaS04) particles, or a combination of such materials. Circle 5A and Figure 5B illustrate a perspective cross-sectional view of the LED-based lighting module 1 as shown in Figure 1. In this embodiment, the sidewall insert 107, the wheel exit window 1 and the bottom reflector insert 106 disposed on the mounting board I 04 define a light-washing cavity 109 in the LED-based lighting module 1 . (Figure

S 161207.doc 201236214 5A). A portion of the light from LED ι 2 is reflected within the light mixing chamber 109 until it exits through the wheel exit window 108. Reflecting the light within the cavity 109 prior to exiting the output window ι 8 has the effect of mixing the light and providing a more even distribution of the light emitted by the LED-based lighting module 100. LEDs 102 can emit different or the same color by direct emission or by phosphor conversion, for example, where a phosphor layer is applied to the LED as part of an LED package. Thus, the illumination device ι can use any combination of colored LEDs 102 (such as red, green, blue, amber or cyan), or the LEDs 102 can all produce the same color of light or some or all of which can produce white Light. For example, LEDs 102 can all emit blue light or uv light. In addition, the LEDs 102 can emit polarized or unpolarized light and the LED-based lighting device 100 can use any combination of polarized LEDs or non-polarized LEDs. When used in combination with a phosphor (or other wavelength converting member), the spheroids (or other wavelength converting members) can be applied to the cavity J, for example, in the output window 8 or on the output window 108. Applied in the bottom reflector 106 or the bottom reflector 1〇6 in the side wall of the 05 or on the side wall of the cavity i 〇5 (such as in the side wall insert 1 〇 7 or on the side wall insert! 〇 7), Or applied to other components (not shown) placed inside the cavity such that the output light of the illumination device 1 has the desired color. The combination of the photoconversion properties of the wavelength converting material and the light within cavity 109 causes the output chirp (e.g., 'output window 〇 8') to emit color converted light. The specific color 161207 of the light output by the output window 108 can be specified by adjusting the chemical and/or physical properties (such as thickness and concentration) of the wavelength converting materials and the geometric properties of the coating on the inner surface of the cavity 109. .doc 201236214 Quality, for example, color point, color temperature, and color rendering index (CRI). Portions of the cavity 109, such as the bottom reflector insert 1〇6, the sidewall inserts, and the cavity 105, may be coated with a wavelength converting material. ffi5B illustrates the portion of the sidewall insert 1〇7 coated with a wavelength converting material. Additionally, portions of the wheeled window 108 may be coated with the same or a different wavelength converting material. Additionally, portions of the bottom reflector insert 106 may be coated with the same or a different wavelength of transition material. In another example (not shown), the sidewall insert 1〇7 is omitted and the inner facing wall of the cavity 105 can be coated with a wavelength converting material. By way of example, the phosphors may be selected from the group indicated by the following chemical formula: YsAisO丨2:Ce (also known as YAG:Ce, or yag for short), (Y,Gd)3Al50,2:Ce, CaS :Eu, SrS:Eu, SrGa2S4:Eu,

Ca3(Sc5Mg)2Si3012:Ce^Ca3Sc2Si3012:Ce^Ca3Sc204:Ce > Ba3Si6012N2:Eu > (Sr,Ca)AlSiN3:Eu > CaAlSiN3:Eu >

CaAlSi(ON)3: Eu, Ba2Si04: Eu, Sr2Si04: Eu, Ca2Si04: Eu, CaSc204: Ce, CaSi2〇2N2: Eu, SrSi202N2: Eu, BaSi202N2: Eu, Ca5(P04)3Cl: Eu, Ba5 (P〇 4) 3ChEu, Cs2CaP2〇7, Cs2SrP207, Lu3Al5012:Ce, Ca8Mg(Si04)4Cl2:Eu, Sr8Mg(Si04)4Cl2:Eu, La3Si6Nu:Ce, Y3Ga5012:Ce, Gd3Ga5012:Ce, Tb3Al5012:Ce,

Tb3Ga50i2: Ce and Lu3Ga5012: Ce. In one example, the adjustment of the color point of the illumination device can be accomplished by replacing sidewall inserts 107 and/or output windows 1〇8 that can similarly coat or impregnate one or more wavelength converting materials. In one embodiment 'a red-emitting phosphor (such as a yttrium-activated geotechnical nitride (eg, (Sr, Ca)AlSiN3:Eu)) covers the sidewall insert at the bottom of the cavity 1〇9 One of the 107 and bottom reflector inserts 106, and - 161207.doc 201236214 YAG scales cover one portion of the output window log. In another embodiment, a red phosphor (such as an alkaline earth oxynitride) is emitted in the cavity! A portion of the sidewall insert 107 and the bottom reflector insert 1 〇6 is covered at the bottom of the crucible 9, and a red-emitting alkaline earth oxynitride nitride and a yellow-emitting YAG phosphor are used to cover the output window 108. Part of it. In some embodiments, the phosphors are mixed with a binder and, optionally, a surfactant and a plasticizer in a suitable solvent medium. The resulting mixture is deposited by spraying, screen printing, knife coating or other suitable means. By selecting the shape and height of the sidewalls defining the cavity, and selecting which of the components of the cavity will be covered with or without the phosphor, and by the surface of the optical mixing cavity 109 The optimization of the layer thickness and density of the phosphor layer can be adjusted as desired to adjust the color point of the light emitted from the module. In an example t' a single type of wavelength converting material can be patterned on a sidewall (which can be, for example, the sidewall insert 丨 07 shown in Figure 5B). By way of example, a red phosphor can be patterned in different regions of the sidewall inserts 1〇7 and a yellow phosphor can cover the output window 1〇8. The coverage and/or concentration of the phosphors can be varied to produce different color temperatures. It should be understood that the coverage of the red phosphors and/or the concentration of the red and yellow fillers will need to be varied for different lighting modules 100. The different lighting modules 100 can produce the same desired color temperature under the blue light changes generated by the LEDs 1〇2 in the different lighting modules. The color performance of the LEDs 102, the red phosphors on the side wall inserts 107, and the yellow phosphors on the output windows 1-8 can be measured prior to assembly and selected based on performance to cause the assembled parts to produce the desired color temperature. 161207.doc

-14· 201236214 In many applications, it is desirable to produce a white light output having a correlated color temperature (CCT) that is less than 4,2 degrees Kelvin (such as less than 3,1 degrees Kelvin). For example, in many applications, white light with a CCT of 2,700 degrees Kelvin is desirable. A certain amount of red light emission is typically required to convert light produced by LEDs emitted from the blue or UV portion of the spectrum into a white light output having one CCT less than 4,2 degrees Kelvin. Efforts are being made to combine yellow phosphors with red-emitting phosphors (such as CaS:Eu, SrS:Ell, SrGa2S4:Eu,

Ba3Si6〇12N2:Eu, (Sr,Ca)AlSiN3:Eu, CaAlSiN3:Eu, CaAlSi(〇N)3:Eu 'Ba2Si04:Eu, Sr2Si04:Eu, Ca2Si04:Eu,

CaSi202N2:Eu, SrSi202N2:Eu, BaSi202N2:Eu, Sr8Mg(Si〇4)4Cl2:Eu 'Li2NbF7:Mn4+ ' Li3ScF6:Mn4+, 1^2〇28:£113 + and]\^0.]^?2. 〇6〇2:^1114+) blend to achieve the desired CCT. However, due to the sensitivity of the CCT of the output light to the red phosphor composition of the blend, the color consistency of the output light is generally poor. In the case of blended phosphors, especially in lighting applications, the poor color distribution is more pronounced. Color consistency can be avoided by coating the output window 1 〇 8 with a phosphor or a light-blown blend that does not contain any of the emitted red phosphors. To produce a white light output having a CCT less than 4,200 degrees Kelvin, a red-emitting phosphor or phosphor blend is deposited in the LED-based lighting module 1 side wall and bottom reflector Any one. The concentration of a particular red-emitting phosphor or phosphor blend (eg, from a peak wavelength of from 600 nm to 70 G nm) and the concentration of the red-emitting phosphor or phosphor blend are selected to produce less than 4,200 Kjeldahl One of the CCT's white light output. In this manner, an LED-based lighting module can produce white light having a CCT of less than 4,200 在 without including an output window that emits one of the red fill components. In some embodiments, any of the bottom reflector 1 〇 6 'cavity ι 5, the output window (10), and the sidewall insert 107 may be constructed of -pTFE material or one facing the optical mixing cavity 109. Any of the 'output window 108, the bottom reflector insert 1〇6, the sidewall insert (10), and the cavity 105 in the example including the _ρτ-item at the inner surface may be made of a pTFE material. In another example, any of output window 〇8, bottom reflector insert 〇6, sidewall insert 107, and cavity 105 can include a lining of a reflective layer, such as a polished metal layer. One of the snoring layers. The PTFE material can be formed from sintered PTFE particles. In some embodiments, a portion of the inner facing surface of any of the bottom reflector 106, the cavity 1〇5, and the sidewall inserts 1〇7 constructed from the —ρτ_ material may be coated The cloth has a wavelength converting material. In other embodiments, a wavelength converting material can be mixed with a PTFE material. For the purposes of this patent document, a wavelength converting material performs a color conversion function (eg, absorbing a certain amount of light of a peak wavelength and, in response, emitting a certain amount of light at another peak wavelength). A chemical compound or a mixture of different chemical compounds. In other embodiments, either of the bottom reflector 1 〇 6, the cavity 1 〇 5, and the sidewall insert 107 may be constructed of a reflective ceramic material such as a ceramic material produced by CerFlex International (Netherlands) or The reflective ceramic material (such as a ceramic material produced by CerFiex International (The Netherlands)) is contained at an inner surface of one of the optical mixing chambers 109. In one example, a bottom reflector 1 〇6, a cavity 1 〇 5, and a sidewall insert I61207.doc -16 · • 3 201236214 107 constructed of a ceramic material (inwardly facing) A portion of any of the surfaces may be coated with a wavelength converting material. In other embodiments, the bottom reflector 106, the cavity 105, and the sidewall insert 107 have a reflective metal A material such as aluminum or Miro® manufactured by Alan〇d (Germany) or an internal surface facing the light mixing chamber 1〇3, such as a reflective metal material (such as aluminum produced by Alan〇d (Germany)) Or 〇8) in any one of the 'inner-facing surfaces of the bottom reflector 丨〇6, the cavity 105 and the sidewall inserts 1〇7 constructed of a reflective metal material, Portions may be coated with a wavelength converting material. In other embodiments, any of bottom reflector 106, cavity 105, and sidewall insert 107 may be constructed of a reflective plastic material (such as mcpet) or facing optical mixing cavity 109. One of the interior surfaces contains the reflective plastic material (such as in an example) A portion of the inner surface of any of the bottom reflector 106, the cavity 105, and the sidewall inserts 1A7 constructed of a reflective plastic material may be coated with a wavelength converting material. The cavity 109 is filled with a non-solid material such as air or an inert gas to cause the LED 102 to emit light into the non-solid material. By way of example, the cavity can be sealed and filled with argon, another Alternatively, nitrogen can be used to fill the cavity 109 by means of a solid encapsulating material. By way of example, polyfluorene can be used to fill the cavity. The PTFE material is less reflective than can be used. Bottom reflector insert 丨%, sidewall insert i 07 or other material of cavity i 05 (such as 161207.doc •17· 201236214 produced by Aian〇d)

Miro®). In one example, the blue light output of an LED-based lighting module 1 having an uncoated Mir〇8 sidewall back member 107 is constructed and sintered by Berghof (Germany). One of the PTFE material constructions was compared to the same module of the uncoated PTFE sidewall insert 1 〇7. By using a PTFE sidewall insert, the blue light output from the module 1 is reduced by 7%. Similarly, an uncoated PTFE sidewall insert 1〇7 was constructed using a sintered PTFE material manufactured by WL Gore (USA) compared to the uncoated Miro® sidewall insert 1 〇7. The blue light output from the module 1 is reduced by 5%. The light extraction from the module 100 is directly related to the reflectivity inside the cavity 1 , 9 and, therefore, the poor reflectivity of the PTFE material will deviate from the use of the PTFE material in the cavity 109 as compared to other available reflective materials. However, the inventors have determined that when a PTFE material is coated with a scale, the PTFE material unexpectedly produces a luminous output compared to other more reflective materials (such as Miro®) having a similar phosphor coating. One of them increases. In another example, a white light output of a phosphor coated Ramir-coated Miro® sidewall insert 1 〇7 is designed for one of Kelvin's 4,000 degrees correlated color temperature (CCT). It is compared to the same module constructed of a phosphor coated PTFE sidewall insert 107 constructed of a sintered PTFE material made by Berghof (Germany). The white light output from the module 1 was increased by 7% by using a phosphor coated PTFE sidewall insert compared to the phosphor coated Miro®. Similarly, white from module 100 was constructed by using a PTFE sidewall insert 107 constructed of sintered PTFE material manufactured by WL Gore (USA) as compared to a filler coated Miro® sidewall insert 107. Light output increased by 14%. In another example, a white light output of the illumination module 100 of one of the phosphor coated 8-side sidewall inserts 107 is targeted to one of Kelvin's 3,000 degrees 161207.doc 18 201236214 correlated color temperature (CCT). It is compared with the same module constructed of a phosphor coated PTFE sidewall insert 1〇7 constructed of a sintered PTFE material made by Berghof (Germany). The white light output from module 100 is increased by 1% by using a phosphor coated pτFE sidewall insert compared to the phosphor coated Miro®. Similarly, a module from the module was constructed using a sintered PTFE# material constructed from WL G〇re (USA) using a pTFMJ wall insert 107 compared to a phosphor coated Miro® sidewall insert 丨07. The white light output of 1〇〇 is increased by 12%. Thus, it has been found that, although less reflective, it is desirable to construct a phosphor-covered portion of the optical mixing cavity 109 from a p-butadiene material. In addition, the inventors have also discovered that phosphor coated pTFE materials are exposed, for example, to a light mixing chamber 109, as compared to other more reflective materials having a similar phosphor coating, such as Miro®. The heat from the LED has better durability. Although it may appear desirable to apply a thick phosphor layer (e.g., a layer thickness greater than five times the average diameter of the illuminant particles) to a substrate to form a reflective or transmissive color conversion element, the inventors have discovered that photons are often trapped Get thick layers and lose efficiency. In contrast, the available light is recovered by color conversion or by an unconverted state by using a thin layer filled with a suitable density. In one aspect, the phosphor can be applied to a thin layer to provide efficient color conversion in a reflective mode and in a transmissive mode. In a reflective mode, the thin layer is densely packed to maximize the amount of color-converted incident light. 161207.doc •19- 201236214. In a transmissive mode, the thin layer is sparsely filled to allow a portion of the incident light to be unconverted. In one example, the phosphorescent system is deposited on a substrate to less than one-fold the thickness of the average diameter of the phosphor particles. In another example, the fill system is deposited on a substrate to a thickness that is less than one-third the average diameter of the phosphor particles. In yet another example, the glazing system is deposited on a substrate in a single layer. In an example where color conversion is provided in a transmissive mode, the phosphorescent system is deposited at a fill density of less than 9% by weight such that a portion of the light incident on the substrate is reflected or transmitted without color conversion. In an example where color conversion is provided in a reflective mode, the phosphorescent system is deposited at a fill density greater than one of 50% such that substantially all of the light incident on the substrate is color converted. In another aspect, the aforementioned thin scale layer is deposited on a PTFE substrate. It has been discovered that a thin layer of spheroidal particles deposited onto a pTFE substrate produces efficient color conversion in an LED based illumination device. Figure 6 is a flow diagram illustrating a method 150 of applying a thin phosphor layer to a reflective substrate. In the illustrated method 15A, a low temperature treatment is employed to deposit a thin layer of phosphor particles on a PTFE substrate. In other examples, method 15() can be employed to deposit a thin disk of light body particles on other reflective surfaces (e.g., glass, aluminum, coated aluminum, ceramic, or plastic substrates). In the low temperature process, a binder and the filler particles are held on the substrate as part of the finished product rather than being decomposed (usually by a high temperature curing step). In block 151, a polymer binder (eg, ethylcellulose) blood-solvent (eg, 'butoxyacetate acetate and with a wavelength converting material 161207.doc -20- 201236214 (eg, vitriger The particles or the phosphor particles are combined to form a homogeneous scale suspension. In some examples, the average particle size of the phosphor particles can be between one micron and twenty-five micrometers. In the 150-part, different polymer binders can be used (for example, vinyl butyral, cellulose-based binder, polyoxyl-based adhesive, and urethane) Similarly, as part of the method 150, a solvent selected for its compatibility with the selected binder may be employed (eg, sterol, isobutanol, butyl sulfonol) a gelatinic acid (butyi earbome aeetate), a butyl cellulose, a polyoxoic acid solvent, and an amine methyl (tetra) solvent. In some embodiments, (iv) light particles may be added in small amounts (for example, by weight) Depending on the plasticizer (for example, phthalic acid) Diisobutyl vinegar) to promote adhesion of the phosphor particles to the substrate. In certain embodiments, a surfactant (eg, stearic acid, polyethylene glycol (PEG)) may be added to the phosphor particles. For example, a small amount of surfactant (eg, less than 5% by weight) may be added. The surface active back I reaction prevents the phosphor particles from coagulating together and promotes the phosphor particles in the suspension. Uniform distribution. In different examples, the ratio of phosphor particles to reduced polymer binder can vary. In the case of - item, the solvent can be reduced with a ratio of _5G: 5G (by weight). Polymer binder mixing. This ratio has been found to be useful for producing a color conversion layer having a packing density greater than 9 G% and having a thickness less than one-fifth the average diameter of the phosphor particles. In another example, phosphorescence The bulk particles can be mixed with a reduced polymer binder in a ratio of 20:80. This ratio has been found to produce less than 161207.doc

S - 21 · 201236214 95% One of the color conversion layers having a packing density and having a thickness less than one third of the average diameter of the phosphor particles is useful. In block 152, a homogeneous phosphor suspension is applied to the _pTFE substrate to form an uncured color conversion layer. The homogeneous disc suspension can be applied to the PTFE substrate by several methods. Examples of suitable methods include knife coating, screen printing, and spraying. The solvent can be mixed with the polymer binder in different proportions depending on the desired viscosity. For example, for effective application to a substrate by knife coating or screen printing, solvent and polymer can be used in a suitable ratio (eg, between 5:1 and 10:1 by weight). The binder is mixed. The solvent can be mixed with the polymer binder in a suitable ratio (e.g., between 1 and 4:2 by weight) for effective application by spraying to a substrate. In some instances, the (four) float can be applied to a surface by knife coating. Use a sapphire or stainless steel spatula to disperse the suspension... The automatic applicator maintains a constant distance between the knife and the surface. A stainless steel template can be used to direct the application of the suspension to a particular portion of the surface (e. g., 'specific pattern or surface geometry). In some instances, a homogeneous suspension can also be applied to the surface by screen printing. 4. Weeks can be customized to completely mask or partially obscure various sizes and shapes. The opening of the screen C7 is public*? The A_P knife contains different aspect ratios to change the concentration of the applied phosphor particles. For screen printing, it has been found that a custom screen with a number of blinks is effective. The pre-cut substrate (10) such as ptfe, sputum, MCpET) is attached to an aluminum pedestal by means of a screen cover. Use a suitable applicator (for example, rubber applicator) to 161207.doc

-22- 201236214 Constant velocity and pressure to disperse a homogeneous suspension of phosphor particles. In block 153, the uncured color conversion layer is heated to a temperature above one of the flash points of the solvent to vaporize the solvent to form one of five times the thickness of one of the average diameters of the phosphor particles. Floor. For example, the uncured color conversion layer is heated to a temperature of from 8 Torr to 15 Torr for 30 to 300 minutes to evaporate the solvent. The treatment temperature is kept below the temperature at which the binder begins to decompose. Thus the cured color conversion layer comprises a layer of thin phosphor particles suspended in a polymeric binder. The polymer binder maintains the phosphor particles in a stable manner relative to each other. Furthermore, the low temperature treatment does not denature or otherwise decompose or change the chemical composition of the glazing, so that its color conversion properties remain intact. This is especially important for certain phosphor families, such as 'nitrosulphonate and oxonium nitride. In addition, 'low temperature processing does not decompose, denature or otherwise degrade the mechanical structure of the PTFE material to maintain its diffuse, reflective properties. The use of the method 150 can effectively use the filler particles of varying diameters. The inventors have found that it is useful to use a filler particle having an average diameter of one of 6 m to 8 m. However, advantageously, phosphor particles having an average diameter between 1 and 25 jaws can also be used. Back to Figure 7 illustrates a flow diagram of a method 160 for applying a thin translucent color conversion layer to a transparent substrate (e.g., sapphire, alumina, glass, polycarbonate 'plastic). In block 161, a polymeric binder (e.g., ethylcellulose) is mixed with a solvent (e.g., butoxyethyl acetate) and combined with the phosphor particles to form a homogeneous phosphor suspension. As part of the method 160, different polymeric binders can be employed (eg, polyethyl b)

I6I207.doc*23' S 201236214 Enol butyral, cellulose-based binder, polyoxyl-based binder, and urethane-based binder). Similarly, as part of the method 160, a solvent selected for its compatibility with the selected binder can be employed (eg, 'terpineol, isobutanol, butyl contiguous acetate, butyl, butyl Cellulose, polyoxyl solvent and ethyl urethane solvent) In some embodiments, a plasticizer (eg, diisobutyl phthalate) may be added in addition to the phosphor particles to promote the phosphor Adhesion of particles to the substrate. In certain embodiments, a surfactant (e.g., stearic acid, PEG) may be added. The surfactant reacts to prevent the phosphor particles from coagulating together and promotes uniform distribution of the phosphor particles in the suspension. In different examples, the ratio of phosphor particles to reduced polymer binder can vary. In one example, the phosphor particles can be mixed with a reduced polymeric binder in a ratio of 95:5 by weight. This ratio has been found to be useful for producing a translucent color conversion layer having a fill density of less than 95% and having a thickness less than one-third the thickness of the average diameter of the phosphor particles, wherein at least 1% of the incident light is transmitted through This layer does not require color conversion. In some instances, less than 3% of incident light is transmitted through the layer without color conversion. In block 162, a homogeneous phosphor suspension is applied to a transparent substrate as discussed with respect to method 15A to form an uncured color conversion layer. A homogeneous phosphor suspension can be applied to the transparent substrate by several methods. Examples of suitable methods include knife coating, screen printing, and spray coating. Solvent and polymer binders can be applied in different proportions depending on the desired viscosity. 161207.doc •24-

201236214 Mixed. For example, for effective application to a substrate by knife coating or screen printing, the solvent can be mixed with the polymer binder in a suitable ratio (for example, between 5q and 10:1 by weight). . For effective application to a substrate by spraying, the solvent can be mixed with the polymeric binder in a suitable ratio (e.g., between 10:1 and 20:1 by weight). In block 163, the uncured translucent color conversion layer is heated to a temperature above one of the flash points of the solvent to vaporize the solvent to form one of five times the thickness of one of five times less than the average diameter of the phosphor particles. Transparent color conversion layer. In some instances, the processing temperature remains below the temperature at which the binder begins to decompose. In one example, the uncured translucent color conversion layer is heated to a temperature of from 100 to 120 degrees Celsius for 30 to 60 minutes to evaporate the butyl acetate acetate solvent. Thus, the cured translucent color conversion layer comprises a layer of thin phosphor particles suspended in a polymeric binder. The polymeric binder maintains the phosphor particles positioned relative to one another in a stable manner. Moreover, the low temperature treatment does not denature or otherwise decompose or alter the chemical composition of the phosphor, so its color conversion properties remain intact. This is especially important for certain phosphor families such as 'nitrosity citrate and oxonium nitride. In some embodiments, the temperature is treated with one that causes the binder to decompose or otherwise variably. By removing the binder, its effect on the efficiency of light transmission through the cured translucent color conversion layer is ineffective. A plasticizer that is resistant to one of the cure temperatures can be used to bond the phosphor particles to the substrate or maintain a uniform phosphor particle distribution in the cured translucent color conversion layer. In one example, one of the temperatures of 36 degrees Celsius can be used to completely decompose a B 161207.doc -25- 201236214-based cellulose binder and a butyrate acetate solvent. The method 160 can be used to effectively utilize phosphor particles of varying diameters. The inventors have found that the use of phosphor particles having an average diameter of from 6 m to 8 m is useful. However, advantageously, a photon particle having an average diameter between the melon and the 25th work can also be used. Figure 8 illustrates a cross-sectional view of an LED-based illumination module 1 including reflective color conversion elements 129 and 130 coated according to method 15 and one transmission color conversion element 133 according to method ι. In one aspect, the LED-based illumination module 1 includes a transmissive color conversion component 133 that includes an optically transparent layer 134 and a translucent color affixed to the optically transparent layer 134. Conversion layer 135. In another aspect, the LED-based illumination module 1 includes a reflective color conversion component 130 that includes a reflective layer 131 and a color conversion layer 13 that is fixed to the reflective layer 13 1 . 2. In another aspect, the LED-based illumination module 1 includes a reflective color conversion component 129 that includes a reflective layer 128 and a color conversion layer 127 that is coupled to the reflective layer 128. In one embodiment, the transmissive color conversion element 133 is an output window 1 〇 8 and reflects the color conversion element 13 〇 the sidewall insert 107. Additionally, in one embodiment, reflective color conversion element 129 is a bottom reflector insert 106. LED 102 emits blue photons that interact with color conversion elements 129, 130, and 133. The transmissive color conversion element 133 provides efficient color conversion in a transmissive mode. Color conversion layer 135 includes a thin layer of thin phosphor applied in accordance with method 160. Transmission of unconverted light is undesirable in luminaires that are infused with UV or sub-UV radiation 161207.doc -26- 201236214 due to health hazards to humans exposed to light radiation at these wavelengths . However, for an LED-based illumination module that is infused with an LED having an emission wavelength in excess of uv, it is desirable that a large percentage of unconverted light (eg, 'blue light emitted from LED 102') passes through the optical mixing cavity 109 and It passes through the output window 1〇8 (eg, 'transmissive color conversion element 133') without color conversion. This promotes high efficiency because it avoids the inherent loss of the color conversion process. The sparsely stacked thin phosphor layer is adapted to color convert a portion of the incident light. For example, it is desirable to allow at least ten percent of incident light to be transmitted through the color conversion layer 135 without conversion. In particular, a color conversion layer has been found to be less than one of the average diameters of one of the phosphor particles and one of the phosphor particles in the polymer matrix having greater than 80%. In one embodiment, the color conversion layer 1 32 is deposited to a thickness of one of more than 90% to a thickness of one of two times the average diameter of the phosphor particles. In this embodiment, the average phosphor particle diameter is between six and eight microns. To deposit the color conversion layer 132 on the reflective layer 131, one or a combination of 50 grams to 1 gram of ethyl cellulose and polyvinyl condensed binder is used to 2 to 600 A suitable solvent such as terpineol, isobutanol, butylsulfonate, or butylcellulose is mixed. The mixture was rolled in a bottle for 2 to 4 days by a slowly moving roller until a clear adhesive paste was formed. The viscosity of the adhesive paste varies with > the granule contains 1. In a separate mixture, from 1 g to 3 g of a surfactant such as stearic acid or polyethylene glycol is mixed in a solvent of 50 g to 100 g to form a surfactant paste. In a final mixture I61207.doc -27- 201236214, gram to 5 grams of red-emitting phosphor particles and 1 to 10 grams of binder paste 'ό. 至 to 0.5 grams of surfactant paste and 2 drops to 1 drop of plasticizer were mixed in a 3D mixer (ΤΗΙΝΚγ ARE_25〇) for 2 to 丨〇 minutes to produce a homogeneous suspension of one of the phosphor particles. The ratio of binder, surfactant, plasticizer and phosphor is adjusted depending on the application. In a more specific example, 1 gram of ethylcellulose binder is mixed with 8 grams of butyl sulfophenolic acetate (BAC) solvent in a glass vial. The mixture was stirred in a glass bottle for several hours and then rolled in a slow moving roller for 2 to 4 days until a clear adhesive paste was formed. In a separate mixture, 1 gram of polyethylene glycol surfactant was mixed in 1 gram of BAC until an optically clear surfactant paste was formed. One gram of an average of 10 micron particle size red-emitting disc {{S, Ca)AlSiN3:Eu} with 1 gram of adhesive paste, 〇. 克 of surfactant paste and 2 drops of plasticizer Mix in a 3D mixer (THINKY ARE-250) for 2 minutes. The color conversion layer 132 can be deposited onto the reflective layer 131 by doctor blade coating. An automatic film applicator (Elcometer 4340) was used with the pre-cut stainless steel template to determine the coverage area. When the reflective layer 13 1 and a template are held on a susceptor under vacuum, a slow moving (eg, '5 to 6 〇mm/sec) sapphire or stainless steel scraper is used to disperse the homogeneous suspension of phosphor particles. . After coating, the reflective color conversion element 130 is transferred to a furnace and heated in an open atmosphere at 80 to 150 degrees Celsius for 1 to 5 hours to form a cured color conversion layer 132. The color conversion layer 13 2 can be deposited onto the reflective layer 3 by screen printing. 161207.doc -28 - 201236214 A mesh with a mesh number of 150 to 300. The screen is completely open or shaded by various sizes and shapes of different aspect ratios. Using the aforementioned automatic film applicator, the reflective layer 13 1 and the desired screen are attached to an aluminum base under vacuum and a suitable extrusion is used at a constant pressure and speed (eg, 5 to 100 mm/sec). A homogeneous suspension of dispersed phosphor particles. After screen printing, the reflective color conversion element 130 is transferred to a furnace and heated in an open atmosphere at 80 to 15 degrees Celsius for 1 to 5 hours to form a cured color conversion. Layer 132 ° After heat treatment, a cured color conversion layer 132 is employed in an LED-based lighting module to produce a CCT having a hungry range of 2 to 6,000 degrees Kelvin. White light. Four 9 illustrates a cross-sectional view of one of the LED illumination modules, one of which focuses on the interaction of photons emitted by LEDs 102 having transmissive color conversion elements 13 3 . The transmissive color conversion element 133 includes a transmissive layer 134 and a translucent color conversion layer 135. The transmission layer 134 can be constructed of an optically transparent medium (e.g., glass, sapphire, polycarbonate, plastic). Transmissive color conversion element 133 may include additional layers (not shown) to enhance optical system performance. In one example, the transmission color conversion element 133 can comprise an optical film (such as a dichroic filter, a low refractive index coating), an additional layer (such as a layer of scattering particles), or an additional color comprising phosphor particles. Conversion layer. The translucent color center conversion layer 135 includes phosphor particles 141 embedded in a polymer binder 14 2 . In one embodiment, the translucent color conversion layer 135 is at a fill density of greater than 8% and is three times the average diameter of the phosphor particles 141.

S -29· 201236214 A thickness T] 35 is deposited on the optically transparent layer 134. The average diameter of the phosphor particles can be between one micron and twenty-five micron. In some instances, the filler particles 141 are on average five to ten microns in diameter. The filler particles 141 are configured such that a portion of the light can be transmitted through the transmissive color conversion element 丨 33 without color conversion. In this embodiment, the particle diameter DAVG is ten microns. In order to deposit the translucent color conversion layer (1) on the optically transparent layer m, 10 g of the ethyl cellulose binder is mixed with the shouted butyl sulfophenolic acetate (BAC) solvent in a glass bottle and Stir in a wide-mouth glass bottle for several hours and then roll in a slowly moving roller for 2 to 4 days until a clear adhesive paste is formed. In a separate mixture, 10 grams of polyethylene glycol surfactant was mixed in 1 gram of BAC until an optically clear surfactant cream was formed. In a final mixture, one gram of a 1 μm average particle size of a yellow-emitting phosphor (such as a gram of binder paste, a gram of surfactant paste, and 2 drops of plasticizer in a 3D mixer) ΤΗΙΝΚγ ARE_25〇) is mixed for 2 minutes. The translucent color conversion layer 135 can be deposited onto the optically transparent layer 134 by knife coating. An automatic film applicator (Eic〇meter 434〇) together with the pre-cut stainless steel template Used to determine the coverage area. When the optically transparent layer i 34 and a template are held under vacuum on an aluminum base, a slow moving (eg, '10 mm/sec) sapphire or stainless steel scraper is used to disperse the phosphor particles. A homogeneous suspension. The translucent color conversion layer 135 can be deposited onto the optical menstrual layer 134 by screen printing. A screen having a mesh number of 15 to 3 inches is used. Screen 161207.doc 201236214 Fully open or shaded by various sizes and shapes of different aspect ratios. Using the aforementioned automatic applicator, the optically clear layer 134 and the desired screen are attached under vacuum to an aluminum base at constant pressure and speed. For example, 2 〇mm/sec) uses a suitable suspension to disperse the phosphor particles. The translucent color conversion layer 丨35 can be deposited onto the optically transparent layer 134 by painting. A low-viscosity slurry is prepared by mixing a yellow phosphor (such as YAG:Ce), a 1.2 gram binder paste, a bismuth surfactant paste, 2 drops of plasticizer, and 10 grams of BAC. A satisfactory result was obtained with a manual spray gun of 50 cc capacity at 10 PSI. After coating, the transmission color conversion element 133 was transferred to a furnace and heated in an open atmosphere at 120 degrees Celsius for 1 hour to form a cured Translucent color conversion layer 1 3 5. After heat treatment, a cured translucent color conversion layer 135 is employed in an LED-based illumination module to have a relationship between Kelvin 2 and Kelvin A white light of a CCT between 6,000 degrees. As shown in Figure 9, the blue photon 139 emitted from the LED 102 passes through the transmission color conversion element 133 without color conversion and contributes to the combined light 14 as a blue Photon. However, since LED 10 The two emitted blue photons 138 are absorbed by one of the phosphor particles embedded in the color conversion layer 135. In response to the stimulus provided by the blue photon 138, the phosphor particles are emitted in an isotropic emission pattern. One of the long wavelengths of light. In the illustrated example, the phosphor particles emit yellow light. As illustrated in Figure 9, the portion of the yellow emission passes through the transmissive color conversion element 133 and contributes to the combined light HO as a yellow Photon. Another part of the yellow emission is adjacent to the phosphorus 161207.doc

S 201236214 Light body particles are absorbed and re-emitted or lost. A further portion of the yellow emission is scattered back into the light mixing chamber 1〇9 (where the portion of the yellow emission is reflected toward the transmissive color conversion element 133) or absorbed and lost in the optical hybrid 1〇9. Figure 10 illustrates a cross-sectional view of a portion of an LED illumination module 100 having a transmissive color conversion element 13 having a color conversion layer 135 having a single layer of phosphor particles 141. In one embodiment, the phosphor particles 141 may be separated by a polymeric binder 142. In another embodiment, the phosphor particles 141 can be deposited on the transmission layer 134 and the polymeric binder 142 removed as set forth in this patent document. In any of the embodiments, the layer thickness T | 3 S is so small that the re-absorption of the converted light by adjacent smear particles is minimized. In addition, the Fresnel loss associated with transmission of light through the color conversion layer 135 is minimized. In addition, the loss due to total internal reflection (TIR) in the color conversion layer 135 is minimized. Thus, it has been found that the disk particles fixed to the transmission layer 134 in a single layer transmit unconverted light and converted light in an efficient manner. For an LED-based lighting module, it is desirable to convert a portion of the light emitted from the LED (eg, the blue light emitted from the LED 102) into a longer wavelength light while making the photon in the light mixing chamber ι〇9 The loss is minimized. The densely packed thin phosphor layer is adapted to effectively color convert a significant portion of the incident light while minimizing losses associated with re-absorption of total internal reflection (TIR) and Fergu effect by adjacent phosphor particles. . Figure U illustrates a cross-sectional view of a portion of a LED illumination module 100 having a reflective color conversion component 130 having a color of one of 161207.doc -32· 201236214

There is a color conversion layer 132 which is less than five times the average diameter of the phosphor particles 141. Phosphor particles 141 may have an average diameter of between twenty and five microns. In certain embodiments, the phosphor particles have a mean diameter between five microns and ten microns. Phosphor particles 5, blue photons 137 emitted from L D 102 are incident on the reflective color conversion element: 30 and are absorbed by the phosphor particles of one of the color conversion layers 132. In response to the stimulus provided by blue photon 137, the phosphor particles emit light of a longer wavelength in an isotropic emission circle. In the illustrated example, the phosphor particles emit red light. As illustrated in Figure ,, one portion of the red emission enters the light mixing cavity 109. Another portion of the red emission is absorbed by the adjacent phosphor particles and re-emitted or lost. A further portion of the red emission is reflected from the reflective layer 131 and transmitted through the color conversion layer 132 to the optical mixing cavity 109 or absorbed by an adjacent phosphor particle and re-emitted or lost. Circle 12 illustrates a cross-sectional view of a portion of a led illumination module 100 having a reflective color conversion element 〇3 〇 having a color conversion layer 132 having a single layer of phosphor particles 141. In one embodiment, the phosphor particles 141 may be separated by a polymer binder 142, for example, as illustrated in the method 150. In another embodiment, the phosphor particles 141 may be deposited on the reflective layer 131. And removed from the polymeric binder 142 as set forth in this patent document. In either embodiment, the layer thickness is so small that the re-absorption of the converted light by adjacent phosphor particles is minimized by 161207.doc -33·201236214. Additionally, the Fresnel loss associated with transmission of light through the color conversion layer 132 is minimized. In addition, losses due to total internal reflection (TIR) within the color conversion layer 132 are minimized. Thus, it has been found that the phosphor particles fixed to the reflective layer 131 in a single layer efficiently convert light. FIG. 13 illustrates a cross-sectional view of an LED lighting module 100 having a transmissive color conversion assembly 144. In the illustrated embodiment, the transmissive color conversion assembly 144 includes a color conversion layer 135 having a single layer of phosphor particles 141. Phosphor particles 141 can be deposited on the transmission layer 134 and the polymeric binder 142 as removed as set forth in this patent document. The color conversion layer 135 is received by a second transmission layer 136 that is sealed to the transmission layer 134 by a sealing member 143. In this way, the color conversion layer 135 is isolated from the environment. In some embodiments, the sealing element 143 can be a frit sealing glass such as a Bi-based glass frit (BSF-1307) without Pb. In some other embodiments, the sealing element 143 can be an optical adhesive (e.g., J-91 Lens Bond type adhesive/optical glue). Figure 14 illustrates a top view of the transmission color conversion assembly 144. In particular, the sealing element 143 is illustrated. Sealing element 143 extends along the perimeter of assembly 144. In this way, the light emitted by the LED-based illumination device 1 is minimally affected by the presence of the sealing element 143. By isolating the color conversion layer 135 from the environment, phosphors that are generally sensitive to environmental factors such as 'humidity can be successfully employed. Moreover, by minimizing the presence of the bonding agent in the color conversion layer 135, the transmissive color conversion assembly 144 can operate at higher temperatures without suffering degradation of optical performance. 161207.doc • 34· 201236214 Figure 15 illustrates the packaging of a thin translucent color conversion layer between two transparent substrates (eg 'sapphire, alumina, glass, polycarbonate, plastic) and sealing the color from the environment One of the conversion layers is a flow chart of one of the methods 17〇. In one aspect, the color conversion layer does not contain a binder or solvent. In this way, although the phosphor is heated during operation, there is no effect on the light efficacy due to degradation of the binder. In another aspect, separating the color conversion layer from the environment permits the use of a wide range of environmentally sensitive phosphors as one of the LED-based lighting modules. In block 171, a polymeric binder (e.g., ethylcellulose) is mixed with a bath (e.g., butoxyethyl acetate) and combined with the phosphor particles to form a homogeneous phosphor suspension. As part of Process 16, a different polymeric binder (eg, polyvinyl butyral, a cellulose based binder, a polyoxyl based binder, and a urethane) may be employed. Based on the binder). Similarly, as part of Method 17, a solution may be employed which is selected for its compatibility with the selected binder (eg, 'terpineol, isobutanol' butyl sulfophenolic acetate, Butyl Cellulose, Polyoxyxyl Solvent, and Ethyl Formate Solvent In some embodiments, a plasticizer (eg, phthalic acid S-isobutyl acrylate) may be added in addition to the phosphor particles. Promotes the bonding of the phosphor particles to the substrate. In some implementations, a surfactant (for example, stearic acid, pEG) may be added. The surface active mx prevents the (4) photo-particles from agglomerating into agglomerates and promoting the phosphor particles. Uniform distribution in the suspension. In different examples, the ratio of phosphor particles to reduced polymer binder can vary. In the case of example t, the scale particles can be -95:5 ratio 161207.doc

S -35. 201236214 (by weight) mixed with reduced polymer binder. This ratio has been found to produce a color conversion layer having a fill density of less than 0.95 and having a thickness less than one-third the thickness of the average diameter of the phosphor particles to produce a semi-transparent color conversion layer (at least 1% of which is incident) Light is transmitted through the layer without the need for color conversion) useful. In block 172, a homogeneous phosphor suspension is applied to a transparent substrate as discussed with respect to method 155 to form an uncured translucent color conversion layer. A homogeneous phosphor suspension can be applied to the transparent substrate by several methods. Examples of suitable methods include knife coating, screen printing, and spray coating. The solvent can be mixed with the polymer binder in different proportions depending on the desired viscosity. For example, for effective application to a substrate by knife coating or screen printing, the solvent can be mixed with the polymeric binder in a suitable ratio (e.g., between 10.1 by weight). For effective application to a substrate by spraying, the solvent can be mixed with the polymeric binder in a suitable ratio (e.g., between 10:1 and 20:1 by weight). In block 143, the uncured translucent color conversion layer is heated to a temperature sufficient to evaporate the bath and denature the binder to form one half of a thickness that is less than one-fifth the average diameter of the phosphor particles. The transparent color conversion layer ^ treatment temperature is maintained at the temperature at which the binder begins to decompose. In one example, the uncured translucent color conversion layer is heated to a temperature of 3 to 35 degrees Celsius for 20 to 30 minutes. In this way, the translucent color conversion layer is composed more largely of phosphor particles in which only trace elements of the binder material remain. 161207.doc -36-

201236214 In block 174, a color conversion layer is received between the first transmissive element and a first transmissive element (e.g., between two glass sheets). A sealing member fixedly affixes the two transmissive elements and accommodates a color conversion layer between the two transmissive elements. In this way, the color conversion element is isolated from the environment. The method 170 can be used to effectively utilize phosphor particles of varying diameters. The inventors have found that the use of photo-particles having an average diameter of 6 to 8 μm is useful. However, advantageously, phosphor particles having an average diameter between i _ and Μ μηη can also be used. Figure 16 illustrates a cross-sectional view of one of the LED lighting modules ι having a color conversion layer 135 disposed on a transmissive layer 134 and encapsulated by a sealing member 145. In the illustrated embodiment, the transmissive color conversion assembly 144 includes a color conversion layer having a single layer of phosphor particles 141. Phosphor particles (4) can be deposited on the transmissive layer 134 and as described in this patent document. In addition to the polymer binder 丨42. The color conversion layer 135 is encapsulated by a sealing member 145. In this way, the color conversion layer 135 is isolated from the environment. In some embodiments, the sealing element 145 can be a metallosilicate (such as sodium sulphate) or any organometallic silicate (such as tetraethoxy hydrazine). In the example, the sealing element (4) can be an optical adhesive (for example Γ [91 = BCHHI type adhesive / optical glue). By isolating the color conversion layer 135 from the environment, phosphors that are generally sensitive to environmental factors such as humidity can be successfully employed. Moreover, by minimizing the presence of the binder in the color conversion layer 135, the color conversion layer 135 can operate at higher temperatures without suffering degradation of optical performance. I61207.doc •37· 201236214 Figure 17 illustrates the encapsulation of a thin translucent color conversion layer on a transmissive substrate (eg, sapphire, alumina, glass, polycarbonate, plastic) and a self-sealing color conversion layer One of the methods 18 is one of the flowcharts. In one aspect, the color conversion layer does not contain a binder or solvent. In this way, although the phosphor is heated during operation, there is no effect on the light efficiency due to degradation of the binder. In another aspect, separating the color conversion layer from the environment permits the use of a wide range of environmentally sensitive phosphors as an element of the LED-based lighting module 100. In block 181, a polymer binder (eg, ethyl cellulose) is mixed with a solvent (eg, butoxyethyl acetate) and phosphorescent as discussed above with respect to methods 155, 16A and 17B. The bulk particles are combined to form a homogeneous light-breaking suspension. In block 182, a homogeneous phosphor suspension is applied to a transparent substrate as discussed with respect to method 55 to form an uncured translucent color conversion layer. In block 183, the 'uncured translucent color conversion layer is heated to a temperature sufficient to evaporate the ridge agent and denature the binder to form a thickness that is less than one-fifth the thickness of the average diameter of the phosphor particles. Translucent color conversion layer. The handling level is maintained at a temperature at which the binder begins to decompose. In the case of the item, the witch cured translucent color conversion layer is heated to a temperature of 3 to 35 degrees Celsius/dish for 10 to 30 minutes. In this way, the translucent color conversion layer is made up of the filler particles of the trace elements in which only the binder material remains. 161207.doc

• 38- 201236214 In block 184, the color conversion layer is encapsulated by a sealing element. The sealing element isolates the color conversion layer 135 from the environment. The use of method 1 80 can effectively utilize phosphor particles of varying diameters. The inventors have found that the use of phosphor particles having an average diameter of from 6 μηη to 8 μηι is useful. However, it is also advantageous to use phosphor particles having an average diameter between i μηι and 25 μηι. Figure 18 illustrates a cross-sectional view of an LED illumination module 1 具有 having a color conversion layer 135 embedded in the surface of the transmission layer I". In the illustrated embodiment, there is a single phosphor particle 141 One of the layers of color conversion layer 135 is embedded in the surface of a transmission layer 134. In one embodiment, the transmission layer 134 is a low softening glass such as a floating glass giass. Deposited on a transmission layer 134 and a polymeric binder 142 as removed as set forth in this patent document. The transmission layer 134 is heated to its glass softening temperature and embeds the phosphor particles 141 into the glass surface. In some instances Pressure is applied to facilitate embedding the phosphor particles in the glass surface. The transmission layer 134 is slowly cooled to relax the internal stress. In this manner, the phosphor particles 141 are fixed to the transmission layer 134 without the need for a binder. The color conversion layer 135 can operate at higher temperatures without affecting optical performance. In some embodiments, the color conversion layer 135 is then encapsulated by a sealing member 145. In this manner, the color conversion layer 135 and the environment are rendered 0 19 illustrates a reflective layer 131 of a snoring material. As illustrated, phosphor particles 141 are embedded in PTFE reflective layer 131. In certain embodiments, phosphor particles 141 are mixed with PTFE particles, And then sintered together to achieve the desired optical structure comprising phosphor particles 141. The reflective layer I61207.doc • 39· 201236214 131 may be subdivided into a plurality of layers. For example, the reflective layer m may comprise no scale light The other-reflective layer of the bulk particles 141 is lined with a reflective layer of one of the four (four) light body particles 141. Although certain specific embodiments have been set forth above for instructional purposes, the teachings of this patent document are generally applicable. And not limited to the specific embodiments described above. For example, any of the sidewall insert 1〇7, the bottom reflector insert 106, and the output window 〇8 can be patterned with the scale. Both the pattern itself and the phosphor composition can vary. In one embodiment, the month device can comprise different types of phosphors positioned at different regions of the light mixing chamber 1 。 9. For example, - Red can light body can be positioned Any or both of the insert 1〇7 and the bottom reflector insert 106 and the yellow and green fill bodies may be positioned on the top or bottom surface of the window 108 or embedded in the window 1〇8. In an embodiment, the central reflector may have a different type of phosphor map t, such as 'one body on one first region and one green phosphor on a separate second region. In another embodiment, Different types of light-filling bodies (for example, red and green) can be positioned on different areas of the proud piece. For example, the type of the light body can be on the side money piece 1 () 7 - the first area The patterning is, for example, in the form of a strip 'spot, dot or other pattern' and the other type of phosphor is positioned on a different second region of the insert 1〇7. If desired, use a different rating in the cavity area..., if it is: right shoulder 1, use only a single type of wavelength conversion material and place it in cavity 1〇9 (for example, on the side wall) Patterned. In another example, FIGS. 4A and 4B illustrate the sidewall as having a -linear configuration, but it should be understood that the sidewall may have any desired 161207.doc 201236214 configuration, eg, curved, non-vertical, tilted, etc. Wait. For example, by using a tapered sidewall for pre-collimation of light to achieve a better transfer efficiency through the optical mixing chamber 1〇9. In another example, the cavity 1〇5 is used to clamp the mounting plate 104 directly to the mounting base 1〇1 without the use of the mounting plate retaining ring 103. In other embodiments, the mounting base 101 and the heat sink 130 can be a single component. In another example, an LED-based lighting module 1 is illustrated in Figures 1, 2, and 3 as part of a lighting fixture 15 . As illustrated in Figure 3, the LED-based lighting module can be part of a spare or retrofit lamp. However, in another embodiment, the LED-based lighting module 1 can be shaped into a spare or retrofit lamp and is considered to be the backup or retrofit lamp. Various modifications, changes and combinations of the various features of the described embodiments can be practiced without departing from the scope of the invention as set forth in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS A circle 1 'Figure 2 and Figure 3 illustrate three exemplary lighting fixtures including a lighting device, a reflector and a light fixture. An illustration of an exploded view of the components of a led-based lighting device as illustrated in FIG. 0 5A and Figure 5B illustrate the figure! A perspective cross-sectional view of one of the LED-based lighting devices depicted therein. A circular 6-system circular solution illustrates one of a flow chart of a method of applying a thin phosphor layer to a reflective substrate. 0 7 is a flow chart of one of the methods of applying a thin translucent color conversion layer to a transparent substrate. 161207.doc 201236214 Figure 8 illustrates a cross-sectional view of a LED-based lighting module including reflective and transmissive color conversion elements coated with a - (iv) photo-layer. Figure 9 illustrates a cross-sectional view of a portion of a led illumination module having a transmissive color conversion element having a color conversion layer having a thickness less than one-fifth the average diameter of the phosphor particles. Figure 10 illustrates a cross-sectional view of a portion of an LED illumination module having a transmissive color conversion element having a color conversion layer having a single layer of phosphor particles. Circle 11 illustrates a cross-sectional view of a portion of an LED illumination module having a reflective color conversion element having a color conversion layer having a thickness less than one-fifth the average diameter of the phosphor particles. Figure 12 illustrates a cross-sectional view of a portion of an LED illumination module having a reflective color conversion element having a color conversion layer having a single layer of phosphor particles. Figure 13 illustrates a cross-sectional view of an lED illumination module having a transmissive color conversion assembly. Figure 4 illustrates a top view of the transmission color conversion assembly shown in Figure 13. Figure 15 is a flow diagram illustrating one method of accommodating a thin translucent color conversion layer between two transparent substrates and sealing the color conversion layer from the environment. Figure 16 illustrates a cross-sectional view of an LED illumination module having a color conversion layer disposed on a transmissive layer and encapsulating a color via a sealing element. Figure 17 is a diagram illustrating a thin translucent color conversion layer encapsulated in a transmission 161207.doc -42·

201236214 Flowchart of one of the methods of sealing the color conversion layer on the substrate and from the environment. 018 illustrates a cross-sectional view of an LED lighting module having a color conversion layer embedded in a surface of the transmissive layer. 0 19 illustrates a reflective layer of one of the PTFE materials. [Main component symbol description] 100 Light-emitting diode-based lighting module 101 Mounting base 102 Light-emitting diode 103 Mounting plate positioning ring 104 Mounting plate 105 Cavity 106 Bottom reflector insert 107 Side wall insert 108 Output Window 109 Light mixing cavity 115 Light source sub-assembly 116 Light conversion sub-assembly 127 Color conversion layer 128 Reflective layer 129 Reflective color conversion element 130 Reflective color conversion element / Luminaire 131 Reflective layer 132 Color conversion layer 133 Transmission color conversion element 161207.doc -43- 201236214 134 Optically transparent layer 135 Translucent color conversion layer 136 Second transmission layer 137 Blue photon 138 Blue photon 139 Blue photon 140 Reflector 141 Side wall 142 Window 143 Sealing element 144 Transmission color conversion assembly 145 Sealing element 150 lighting fixtures 161207.doc -44-

Claims (1)

201236214 VII. Patent Application Range: 1. A device comprising: a light source subassembly having a plurality of light emitting diodes (LEDs); and a reflective color conversion element comprising a polytetrafluoroethylene (pTFE) layer And a first color conversion layer fixed to the PTFE layer, wherein the first color conversion layer comprises a plurality of first type phosphor particles embedded in a polymer matrix, and wherein the first color conversion layer A thickness is less than five times the average diameter of one of the filler particles. 2. The device of claim 1, further comprising: a transmissive color conversion element comprising an optically transparent layer and a second color conversion layer affixed to the optically transparent layer, wherein the second color conversion layer comprises embedded in a plurality of second filler particles of a second type in a second polymer matrix, wherein one of the thicknesses of the second color conversion layer is less than three times the average diameter of the second phosphor particles, and Wherein one of the second phosphor particles in the second polymer matrix has a filling degree of less than ninety percent β. 3. The apparatus of claim 2, wherein the transmission is less than thirty percent incident to the The transmission color conversion element is lighted in winter without color conversion. 4. The device of claim 1, wherein the first type of the scale particles are between five and twenty microns in diameter. 5. The device of claim 2, wherein the reflective color conversion component is a replaceable sidewall insert of a lighting module based on the color conversion property of the replaceable sidewall insert The transmissive color conversion component is selected to be an LED-based illumination module replaceable output 161207.doc S 201236214 window, wherein the S-replaceable output window is selected for its color conversion properties. 6. The device of claim 2, wherein the first color conversion layer and the second color conversion layer comprise less than one-fifth of a plasticizer and one color conversion layer per weight of each color conversion layer The weight is less than one-five percent of the surfactant. 7. The device of claim 2, wherein at least one of the first color conversion layer and the second color conversion layer is a single layer of one of phosphor particles. 8. The device of claim 2, wherein any of the first color conversion layer and the second color conversion layer comprises light scattering particles. 9. The device of claim 1, wherein at least one of the reflective color conversion element and the transmissive color conversion element A further comprises a plurality of third type phosphor particles. 10. The apparatus of claim </RTI> wherein the polymer matrix is selected from the group consisting of ethyl cellulose and polyvinyl butyral. 11 . An apparatus comprising: a light source subassembly having a plurality of light emitting diodes (LEDs); a reflective color conversion element comprising a layer of polytetrafluoroethylene (PTFE) and being fixed to the PTFE layer a first color conversion layer, wherein the first color conversion layer comprises a plurality of first type phosphor particles embedded in a polymer matrix, and wherein one of the first color conversion layers has a thickness smaller than the scale a transmission color conversion element comprising an optically transparent layer and a second color conversion layer fixed to one of the optically transparent layers, wherein the second color is 161207.doc 201236214 Wherein the second one of the translating layers comprises a plurality of phosphor particles of a second type, and the disc particles of the type shai have a wavelength of not more than 600 nanometers. 12. 13. 14. 15. The device of claim U, wherein at least one of the first color conversion layer and the second color conversion layer has less than the first color conversion layer and the second color conversion layer One tenth of the average diameter of the phosphor particles within the thickness. The apparatus of claim 11, wherein the light transmitted through the second color conversion layer has a correlated color temperature of less than 4,200 degrees Kelvin. An apparatus comprising: a plurality of light emitting diodes (LEDs); a transmissive color conversion assembly 'which is positioned to receive light emitted from the plurality of LEDs, the transmissive color conversion assembly comprising: a first transmission An optical element; a second transmissive optical element; a first color conversion material disposed between the first transmissive optical element and the second transmissive optical element; and a sealing material disposed on the first transmissive optical element Between the second transmissive optical element and the second transmissive optical element, the first transmissive optical element is fixedly coupled to the second transmissive optical element, wherein the first transmissive optical element is the first transmissive optical element and the second transmissive optical element The optical element and the sealing material are included. The device of claim 14, further comprising: a reflective color conversion element comprising a second color conversion material. 16I207.doc 201236214 16. The apparatus of claim 14, wherein the first color conversion material comprises a plurality of phosphor particles of a first type, and wherein the first transmitted light cattle and the second transmissive optical element are disposed The thickness of one of the first color conversion materials 'buckets' is less than the average diameter of one of the phosphor particles. 17. The apparatus of claim 6, wherein the thickness of the first color conversion material disposed between the first transmission optical element and the first transmission optical element is less than three of the average diameter of the filler particles Times. The apparatus of claim 14, wherein the first color conversion material disposed between the first transmission optical element and the first transmission optical element has a peak emission wavelength of not more than 6 〇〇, and The light transmitted through the transmission color conversion assembly has a correlated color temperature that is less than one of Kelvin's 4,2 turns. 19. The device of claim 15 wherein the second color conversion material is embedded in a polymer matrix. 20. The invention of claim 15 wherein the second color conversion material comprises a plurality of phosphor particles and the thickness of the second color conversion material is less than three times the average diameter of one of the phosphor particles. 21. A method comprising: mixing a polymer binder with a solvent and a plurality of bowls of particles to form a homogeneous suspension of the phosphor particles - applying the homogeneous suspension to one of the substrates Surface to form an uncured color I conversion layer 'where the substrate system, polytetrafluoroethylene (pTFE) material; 161207.doc 4 ... S 201236214 heating the uncured color conversion layer to evaporate the solvent to form a Curing a color conversion layer, wherein the cured color conversion layer comprises the phosphor particles suspended in the polymer binder, and wherein one of the cured color conversion layers has a thickness less than an average diameter of the phosphor particles Five times. 22. The method of claim 21, wherein the heating involves heating the uncured color conversion layer to no more than three degrees Celsius. 23. The method of claim 21, wherein the polymeric binder is selected from the group consisting of ethyl cellulose and polyvinyl butyral. The method of claim 2, wherein the solvent is selected from the group consisting of butyl sulfonate phenol acetate and acenamyl alcohol. 25. The method of claim 2, wherein the mixing involves mixing phosphor particles in a ratio of not less than one-twentieth by weight and a solvent of not less than 80% by weight and the polymer binder. 26. The method of claim 21, wherein the mixing further involves mixing a plasticizer to form the homogeneous suspension of the filler particles. 27. The method of claim 21, wherein the mixing further involves mixing a surfactant to form the homogeneous suspension of the phosphor particles. 28. The method of claim 21, wherein the applying involves any of spraying, knife coating, and screen printing. 29. The method of claim 21, wherein the thickness of the cured color conversion layer is a single layer of the ones of the optical particles. 30. The method of claim 21, wherein one of the cured color conversion layers has a fill density greater than 50%. The method of claim 21, wherein the average diameter of the phosphor particles is between five microns and twenty microns. 32. The method of claim 21, wherein the surface is an interior surface of an LED-based illumination module. 161207.doc -6-