WO2010059533A1 - Module de diode électroluminescente à adaptation de couleur en trois parties - Google Patents

Module de diode électroluminescente à adaptation de couleur en trois parties Download PDF

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Publication number
WO2010059533A1
WO2010059533A1 PCT/US2009/064492 US2009064492W WO2010059533A1 WO 2010059533 A1 WO2010059533 A1 WO 2010059533A1 US 2009064492 W US2009064492 W US 2009064492W WO 2010059533 A1 WO2010059533 A1 WO 2010059533A1
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WO
WIPO (PCT)
Prior art keywords
emitting diode
light emitting
light
wavelength converting
color point
Prior art date
Application number
PCT/US2009/064492
Other languages
English (en)
Inventor
Gerard Harbers
Peter K. Tseng
Christopher R. Reed
Original Assignee
Xicato, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Xicato, Inc. filed Critical Xicato, Inc.
Priority to KR1020157033044A priority Critical patent/KR101645153B1/ko
Priority to JP2011537525A priority patent/JP5650655B2/ja
Priority to CA2743149A priority patent/CA2743149C/fr
Priority to KR1020147031873A priority patent/KR20140148486A/ko
Priority to BRPI0916145A priority patent/BRPI0916145A2/pt
Priority to MX2011005343A priority patent/MX2011005343A/es
Priority to EP09752701.4A priority patent/EP2347454B1/fr
Priority to CN200980146272XA priority patent/CN102217107A/zh
Publication of WO2010059533A1 publication Critical patent/WO2010059533A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/50—Wavelength conversion elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/60—Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
    • F21K9/64—Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/60—Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
    • F21K9/62—Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction using mixing chambers, e.g. housings with reflective walls
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V9/00—Elements for modifying spectral properties, polarisation or intensity of the light emitted, e.g. filters
    • F21V9/40—Elements for modifying spectral properties, polarisation or intensity of the light emitted, e.g. filters with provision for controlling spectral properties, e.g. colour, or intensity
    • F21V9/45—Elements for modifying spectral properties, polarisation or intensity of the light emitted, e.g. filters with provision for controlling spectral properties, e.g. colour, or intensity by adjustment of photoluminescent elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L22/00—Testing or measuring during manufacture or treatment; Reliability measurements, i.e. testing of parts without further processing to modify the parts as such; Structural arrangements therefor
    • H01L22/10—Measuring as part of the manufacturing process
    • H01L22/12—Measuring as part of the manufacturing process for structural parameters, e.g. thickness, line width, refractive index, temperature, warp, bond strength, defects, optical inspection, electrical measurement of structural dimensions, metallurgic measurement of diffusions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/50—Wavelength conversion elements
    • H01L33/501—Wavelength conversion elements characterised by the materials, e.g. binder
    • H01L33/502—Wavelength conversion materials
    • H01L33/504—Elements with two or more wavelength conversion materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/58—Optical field-shaping elements
    • H01L33/60—Reflective elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2103/00—Elongate light sources, e.g. fluorescent tubes
    • F21Y2103/30—Elongate light sources, e.g. fluorescent tubes curved
    • F21Y2103/33—Elongate light sources, e.g. fluorescent tubes curved annular
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/0001—Technical content checked by a classifier
    • H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S362/00—Illumination
    • Y10S362/80—Light emitting diode

Definitions

  • This invention relates to the field of general illumination, and more specifically, to illumination devices using semiconductor based lighting elements such as light emitting diodes (LEDs).
  • LEDs light emitting diodes
  • illumination devices that use LEDs typically have spatial and/or angular variations in the color. Additionally, illumination devices that use LEDs are expensive due to, among other things, the necessity of required color control electronics and/or sensors to maintain the color point of the light source or using only a small selection of produced LEDs that meet the color and/or flux requirements for the application.
  • a light emitting diode module is produced using at least one light emitting diode (LED) and at least two selectable components that are a part of a light mixing chamber that surrounds the LEDs and includes an output port.
  • a first selectable component has a first type of wavelength converting material with a first wavelength converting characteristic and a second selectable component has a second type of wavelength converting material with a different wavelength converting characteristic.
  • the first and second wavelength converting characteristics alter the spectral power distribution of the light produced by the LED to produce light through the output port that has a color point that is a predetermined tolerance from a predetermined color point.
  • a set of LED modules may be produced such that each LED module has the same color point within a predetermined tolerance.
  • the LED module may be produced by pre- measuring the wavelength converting characteristics of the different components selecting components with wavelength converting characteristics that convert the spectral power distribution of the LED to a color point that is a predetermined tolerance from a predetermined color point.
  • Fig. 1 illustrates a perspective view of an embodiment of a light emitting diode module.
  • Fig. 2 illustrates a perspective, exploded view of the LED module from Fig. 1.
  • Fig. 3 illustrates a cross-sectional view of an embodiment of the light mixing chamber of the LED module of Fig. 1 with multiple sidewall inserts and windows.
  • Fig. 4 shows a (uV) chromacity diagram, which is also known as the CIE 1976 UCS (uniform chromacity scale) diagram.
  • Fig. 5 illustrates example target color points and tolerance metrics on the CIE 1976 UCS diagram.
  • Fig. 6 is a flow chart illustrating the part of the assembly process for an LED module.
  • Fig. 7 is a diagram illustrating color points of LED modules and predetermined targets on the black-body curve from the CIE 1960 diagram where the X axis represents CCT and the Y axis represents the degree of departure ( ⁇ uv) from the black-body curve.
  • Fig. 8 illustrates a set of LED modules that all produce the same color point within a predetermined tolerance using wavelength converting components having differing wavelength convertin 1 gO characteristics.
  • Fig. 9 illustrates a board with a plurality of packaged LEDs having differing wavelengths.
  • Fig. 1 illustrates a perspective view of an embodiment of a light emitting diode (LED) module 100
  • Fig. 2 illustrates a perspective, exploded view of the LED module 100.
  • an LED module is not an LED, but is an LED light source or fixture or component part of an LED light source or fixture and contains an LED board, which includes one or more LED die or packaged LEDs.
  • the LED module 100 is similar to the LED illumination device described in U.S. Serial No. 12/249,874, entitled “Illumination Device with Light Emitting Diodes", filed October 10, 2008, by Gerard Harbers, which has the same assignee as the present application and the entirety of which is incorporated by reference herein.
  • the LED module 100 includes a base 110 and a top section 120, which may be manufactured from highly thermally conductive material, such as an aluminum based material.
  • the base 110 includes a board 112 with a plurality of LEDs 114 that may be symmetrically arranged.
  • the LEDs 114 are packaged LEDs, such as the Luxeon Rebel manufactured by Philips Lumileds Lighting. Other types of packaged LEDs may also be used, such as those manufactured by OSRAM (Ostar package), Luminus Devices (USA), or Tridonic (Austria).
  • a packaged LED is an assembly of one or more LED die that contains electrical connections, such as wire bond connections or stud bumps, and possibly includes an optical element and thermal, mechanical, and electrical interfaces.
  • the LEDs 114 may include a lens over the LED die. Alternatively, LEDs without a lens may be used.
  • the board 112 provides electrical and thermal contact with the LEDs 114.
  • the board 112 is also in thermal contact with the base 110, which acts as a heat sink.
  • the board may be an FR4 board, e.g., that is 0.5mm thick, with relatively thick copper layers, e.g., 30 ⁇ m to lOO ⁇ m, that serve as thermal contact areas.
  • the board 104 may be a metal core printed circuit board (PCB) or a ceramic submount with appropriate electrical connections.
  • PCB metal core printed circuit board
  • Other types of boards may be used, such as those made of alumina (aluminum oxide in ceramic form), or aluminum nitride (also in ceramic form).
  • the board 112 may include a reflective top surface or a reflective plate 113 may be mounted over the top surface of the board 112.
  • the reflective plate 113 may be made manufactured from a material with high thermal conductivity, such as an aluminum based material that is processed to make the material highly reflective and durable.
  • a material referred to as Miro®, type Miro 27 Silver, manufactured by Alanod, a German company may be used.
  • the base 110 may be produced from multiple pieces.
  • the base 110 may include a lower section 116 through which electrical connection to the board 112 is made and an upper section 118 that is attached to the lower section 116, e.g., by screws 117 (shown in Fig. 1), bolts, or other appropriate attachment mechanism.
  • the upper section 118 may include an aperture 119 into which the board 112 and LEDs 114 extends.
  • the top section 120 includes a center aperture 122 that extends through the top section 120.
  • the top section 120 is attached to the base 110 by screws 124, bolts, or other appropriate attachment mechanism.
  • the top section 120 may be screwed onto the base 110 if desired.
  • An output port is defined by the center aperture 122 and is covered with a window 130 that is mounted to the upper surface of the top section 120, e.g., by epoxy, silicone or other appropriate attachment mechanism.
  • the window 130 may be transparent or translucent to scatter the light as it exits.
  • the window 130 may be manufactured from an acrylic material that includes scattering particles, e.g., made from TiO2, ZnO, or BaSO4, or other materials that have low absorption over the full visible spectrum.
  • the window 130 may be a transparent or translucent plate with a micro structure on one or both sides.
  • the microstructure may be a lenslet array, or a holographic microstructure.
  • the window 130 may be manufactured from AlO 2 , either in crystalline form (Sapphire) or on ceramic form (Alumina), which is advantageous because of its hardness (scratch resistance), and high thermal conductivity.
  • the thickness of the window may be between e.g., 0.5 and 1.5 mm.
  • the window may have diffusing properties. Ground sapphire disks have good optical diffusing properties and do not require polishing.
  • the diffuse window may be sand or bead blasted windows or plastic diffusers, which are made diffusing by dispersing scattering particles into the material during molding, or by surface texturing the molds.
  • a sidewall insert 126 may be positioned within the center aperture 122 of the top section 120 to define the sidewalls. Alternatively, the sidewalls may be defined by the walls of the aperture 122 itself.
  • the sidewall insert 126 may be, e.g., manufactured from a material referred to as Miro®, type Miro 27 Silver, manufactured by Alanod, a German company.
  • the sidewall insert 126 may be produced as a strip of material that is bent to form a ring shape.
  • a light mixing chamber 101 is defined by the sidewalls of the center aperture 122 of the top section 120, e.g., the sidewall insert 126, along with the window 130 and the reflective bottom surface, e.g., the reflective plate 113 on the board 112 of the base 110, which are, therefore, sometimes collectively referred to as components of the chamber 101.
  • the light mixing chamber 101 of the LED module 100 may be formed from different or additional components.
  • the light mixing chamber 101 of the LED module 100 is illustrated as being formed from the reflective plate 113, two sidewall inserts, a top sidewall insert 126 and a bottom sidewall insert 127, and two windows, a top window 130 and a bottom window 131.
  • At least two of the components of the chamber 101 are coated or impregnated with different wavelength converting materials, and are sometimes referred to herein as wavelength converting components.
  • the different types of wavelength converting materials on the wavelength converting components have different wavelength converting characteristics.
  • the window 130 may be coated with a first type of wavelength converting materials 132 that, e.g., converts blue light to yellow light
  • the sidewall insert 126 may be coated with second type of wavelength converting material 128 that, e.g., converts blue light to red light.
  • the sidewall insert 126 is not used and the sidewalls of the center aperture 122 are coated with a wavelength converting material.
  • the reflective plate 113 may be coated with wavelength converting material that may be the same or differ from the other wavelength converting materials on other wavelength converting components.
  • the top and bottom sidewall inserts 126, 127 and/or windows 130, 131 may be coated with different wavelength converting materials. Thus, a portion of the converted light from window 130 will be transmitted into the light mixing chamber 101 through the bottom window 131.
  • the wavelength converting materials may be phosphor or luminescent dyes, which will be generally referred to herein as phosphor for the sake of simplicity.
  • the phosphors used as the wavelength converting materials may be chosen from the set denoted by the following chemical formulas: Y 3 AIsO 12 ICe, (also known as YAG:Ce, or simply YAG), Lu 3 AIsO 12 (also known as LuAG:Ce, or simply LuAG), (Y 5 Gd) 3 AlsO 12 :Ce, CaS :Eu, SrS :Eu, SrGa 2 S4:Eu, Ca 3 (Sc,Mg) 2 Si 3 0 12 :Ce, Ca 3 Sc 2 Si 3 O 12 ICe, Ca 3 Sc 2 0 4 :Ce, Ba 3 Si 6 O 12 N 2 IEu, (Sr 5 Ca)AlSiN 3 :Eu, CaAlSiN 3 :Eu.
  • the phosphor or combination of phosphors may be mixed as a dispersion in a binder for application to a surface by spray painting, screen printing, stenciling, or doctor blading techniques. These techniques are useful to deposit small dots of phosphor, stripes of phosphor, or to uniformly coat the surface.
  • the phosphor or combination of phosphors may also be mixed in powder form with small pellets of binding material for application to a surface, e.g., by spraying or by application of an electric field, as part of a powder coating process.
  • the small pellets have a low melting point and uniformly coat the surface when heated to the melting point of the binder.
  • the LED module 100 may produce a predetermined or target color point with a high degree of accuracy.
  • Fig. 4 shows a (uV) chromacity diagram, which is also known as the CIE 1976 UCS (uniform chromacity scale) diagram.
  • the CIE 1976 UCS diagram illustrates the chromacities of a black- body radiator by curve 200, which is sometimes referred to as the Planckian locus.
  • light sources produce light that lies on the black-body curve 200 at a target color point.
  • producing light at a target color point on the black-body curve 200 is difficult, particularly with an LED light source because of the lack of precise control over the light output of an LED light source manufactured using current processes.
  • target color points 256-258 are illustrated as exemplary target color points and the degree of departure from the target color point is referred to in units of ⁇ u'v' .
  • the color point of a light source varies significantly from a predetermined target color point, the color of the light will be perceptively different from the desired color.
  • light sources are near each other, e.g., in accent lighting or a display, even slight color differences are noticeable and considered undesirable.
  • the MacAdam ellipse generally refers to a region on a chromaticity diagram that contains all colors that are indistinguishable to the average human eye from the color at the center of the ellipse.
  • the MacAdam ellipse is based on empirically based "just noticeable differences" between colors. Because the human eye is more sensitive to some colors than others, the size of the MacAdam ellipse may differ depending on its location in the chromaticity space. Fig.
  • FIG. 5 illustrates 1, 2, 3, and 4 step MacAdam ellipses 250, 252, and 254 around target color points 256, 257, and 258, respectively, in a u'v' CIE 1976 UCS diagram.
  • Another measure of variation from a target color point is a degree of departure ⁇ u'v' from the target color point.
  • the target color point may be color point 256 on the black-body curve and all color points within circle 251 exhibit a degree of departure ⁇ u'v' that is less than 0.0035.
  • circles 253 and 255 illustrate degrees of departure less than 0.0035 about target color points 257 and 258, respectively.
  • a degree of departure ⁇ u'v' that is less than 0.0035 is approximately equivalent to a two-step MacAdam ellipse, illustrated by the lighter circles.
  • Circle 259 illustrates a degree of departure ⁇ u'v' that is less than 0.009 about color point 257.
  • the specification for color of light output by LED module 100 can be expressed as a color within a predetermined tolerance of a target color point.
  • LED module 100 may achieve a particular target color point within a two-step MacAdam ellipse. In another example, LED module 100 may achieve a particular target color point within a degree of departure ⁇ u'v' less than 0.009. Both larger and smaller predetermined tolerance levels may be achieved with LED module 100 if desired.
  • An LED is typically binned after a production run based on a variety of characteristics derived from their spectral power distribution.
  • the cost of the LEDs is determined by the size (distribution) of the bin. For example, a particular LED may be binned based on the value of its peak wavelength.
  • the peak wavelength of an LED is the wavelength where the magnitude of its spectral power distribution is maximal. Peak wavelength is a common metric to characterize the color aspect of the spectral power distribution of blue LEDs. Many other metrics are commonly used to bin LEDs based on their spectral power distribution (e.g. dominant wavelength, xy color point, uv color point, etc.). It is common for blue LEDs to be separated for sale into bins with a range of peak wavelength of five nanometers.
  • LED module 100 includes a board 112 with a plurality of LEDs LEDs 114.
  • the plurality of LEDs 114 populating board 112 are operable to produce light with a particular spectral power distribution.
  • the color aspect of this spectral power distribution may be characterized by its centroid wavelength.
  • a centroid wavelength is the wavelength at which half of the area of the spectral power distribution is based on contributions from wavelengths less than the centroid wavelength and the other half of the area of the spectral power distribution is based on contributions from wavelengths greater than the centroid wavelength.
  • the centroid wavelengths for a plurality of boards each having a number of LEDs, e.g., eight LEDs will differ by lnm or more.
  • the centroid wavelengths will differ by 0.5nm or more.
  • costs increase significantly by producing boards with a closely matched centroid wavelengths.
  • the LED module 100 can accommodate LEDs with a wide spectral power distribution while still achieving a target color point within a predetermined tolerance.
  • multiple LED modules 100 may be produced, each with one or more LEDs having different spectral power distributions, e.g., a deviation in centroid wavelengths of 0.5nm to l.Onm or more, while still achieving closely matched color points from one LED module 100 to the next and, where the matching color points of the LED modules 100.
  • the color points from the LED modules 100 may also be within a predetermined tolerance from a target color point. Thus, less expensive LEDs may be used.
  • the color point of the light emitted by the LED module 100 may be accurately controlled. For example, during assembly of the LED module 100, the two or more wavelength converting components may be selected based on their wavelength converting characteristics and the spectral power distribution of the light produced by the LEDs 114 so that the resulting light that is transmitted through the window 130 has a color point that is within a predetermined tolerance of a predetermined target color point.
  • the wavelength converting components of the LED module 100 may be selected to produce a desired degree of departure ⁇ u'v' of between 0.009 and 0.0035 and smaller if desired, such as 0.002.
  • LED modules 100 having light sources with centroid wavelengths that differ by more than l.Onm may be produced using selected wavelength converting components to produce a degree of departure of ⁇ u'v' of 0.007 or less, such as 0.0035.
  • the wavelength converting components may be selected to produce a degree of departure of ⁇ u'v' of 0.0035 or less.
  • the CIE 1960 UCS color space has generally been superseded by the CIE 1976 UCS as an expression of uniform chromaticity space. However, the CIE 1960 UCS color space is still useful as an expression of chromaticity because the isothermal lines of correlated color temperature (CCT) are lines aligned perpendicular to the Planckian locus. Producing a target color point is desirable for light sources in general. For example, when used for purposes of general illumination, it is desirable that the LED module 100 produce white light with a particular correlated color temperature (CCT).
  • CCT relates to the temperature of a black-body radiator and temperatures between 2700K and 6000K are typically useful for general illumination purposes.
  • CCTs of 2700K, 3000K, 3500K, 4000K, 4200K, 5000K, 6500K on the black body curve or a CCT in illuminant series D are often desirable.
  • CIE CIE
  • the degree of departure is the distance between the color point of the light produced by the light source and the Planckian locus along a line of constant CCT.
  • the degree of departure is referred to in units of ⁇ uv.
  • the color point of a white light source may be described as a CCT value and a ⁇ uv value, i.e., the degree of departure from the black-body curve as measured in the CIE 1960 color space. It follows that the specification for color of light output by LED module 100 can be expressed as a CCT value within a predetermined tolerance and a ⁇ uv value within a predetermined tolerance.
  • Fig. 6 is a flow chart illustrating a part of the assembly process for an LED module 100.
  • a plurality of each of the wavelength converting components are produced with varying wavelength converting properties (302 and 304).
  • the wavelength converting components may be produced by the entity that assembles the LED module 100 or by an external entity that then provides the wavelength converting components to the entity that assembles the LED module 100.
  • the different wavelength converting characteristics of the wavelength converting components are produced, e.g., by varying the concentration and/or the thickness of the wavelength converting material on or in the components.
  • the concentration and/or the thickness of the wavelength converting material may be varied to produce components with wavelength converting characteristics that differ by 0.001 ⁇ uv (in the CIE 1960 diagram) or less.
  • a plurality of windows 130 may be produced, with different concentrations and/or thicknesses of yellow wavelength converting material 132.
  • a plurality of sidewall inserts 126 (or reflective plate 113) may be produced, with different concentrations and/or thicknesses of red wavelength converting material 128.
  • the same formulation of wavelength converting material may be used for each component, e.g., the sidewall inserts 126 or windows 130, but with differing concentrations and/or thicknesses.
  • wavelength converting material may be used, e.g., different mixtures of various wavelength converting materials may be used.
  • the sidewall inserts 126 may be coated with a wavelength converting material 128 having differing ratios of red and yellow phosphors with the same or different concentrations and thicknesses.
  • different areas of the component may be coated with different wavelength converting materials.
  • the same concentration and thickness may be used, but with differing amounts of coverage area on the component, e.g., the amount of uncovered portion of the sidewall insert may vary.
  • the wavelength converting characteristics of the plurality of the wavelength converting components are measured (306 and 308).
  • the wavelength converting components are placed on a test fixture, which includes a light source, e.g., a board 112 with LEDs 114, that produces light with a known spectral power distribution and color point.
  • the wavelength converting components are separately placed on the test fixture and the color point shift is measured using, e.g., a spectrometer and an integrating sphere. If desired, an intensity measurement using a dichroic filter can be done as well as or instead of the integrating sphere measurement, or a colorimeter such as produced by Konica- Minolta (CL-200 colorimeter) can be used.
  • the measured wavelength converting characteristics for each component is stored.
  • a self referencing measurement may be used for the wavelength converting characteristics of the components. For example, color point produced by the full spectral power distribution of the LEDs 114 and the measured component may be compared to the color point produced by the spectral power distribution that excludes the wavelength converted light to produce a self referencing ⁇ uv value.
  • the color point shift of the wavelength converting components is illustrated in the CIE 1976 diagram of Fig. 4.
  • the color point of the test light source which produces blue light at, e.g., 445nm, is illustrated as point 210 in the diagram.
  • the color point produced by, e.g., the wavelength converting material on or within the sidewall insert 126 is illustrated as point 220, which corresponds with a dominant wavelength of, e.g., 630nm.
  • the color point shift produced by the sidewall insert 126 with the test light source is along the dotted line 222, where the amount of the shift will depend on the geometry of the light mixing chamber 101 and the thickness and/or concentration of the wavelength converting material 128 on the sidewall insert 126.
  • the measured color point produced by one of the sidewall inserts 126 with the test light source is illustrated by point 224 and the shift ⁇ u'v' from the color point produced by the test light source without the sidewall insert 126 (e.g., point 210) is illustrated by line 226.
  • the color point produced by, e.g., the wavelength converting material on or within the window 130 is illustrated as point 230 which corresponds with a dominant wavelength of, e.g., 570nm.
  • the color point shift produced by a window 130 with the test light source is along the dotted line 232 depending on the thickness and/or concentration of the wavelength converting material 132 on the window 130.
  • the measured color point produced by one of the windows 130 with the test light source is illustrated by point 234 and the shift ⁇ u'v' from the color point produced by the test light source without the window 130 (e.g., point 210) is illustrated by line 236.
  • different formulations of the wavelength converting materials on a wavelength converting component may also be used, which would alter the color point produced by the wavelength converting materials (as illustrated by arrow 240), and thus, the slope of the color point shift.
  • LEDs that are supposed to produce blue light at 452nm will typically produce light that may range between 450nm and 455nm or more.
  • LEDs that are supposed to produce blue light may produce light that ranges between 440nm and 475nm.
  • the spectral power distribution from one LED to another may be as much as 8%. Accordingly, during the assembly process, the spectral power distribution and/or color point of the LEDs 114 in the base 110 may be measured for each LED module 100 (310 in Fig. 6). The variation in the spectral power distribution of LEDs is one of the reasons why producing LED based light sources with consistent and accurate color points is difficult.
  • the LED module 100 includes two or more wavelength converting components with wavelength converting characteristics that can be individually selected, appropriate wavelength converting characteristics of the components can be selected for a large variation of spectral power distributions of LEDs 114 to produce a color point that is within a predetermined tolerance, e.g., a ⁇ u'v' of less than 0.0035, from a target color point.
  • the target color point may be, e.g., a CCT of 2700K, 3000K, 4000K, or other temperature on the black-body curve, or alternatively, the target color point may be off of the black-body curve.
  • Fig. 7 is a diagram illustrating color points of LED modules and predetermined target color points on the black-body curve from the CIE 1960 UCS diagram where the X axis represents CCT and the Y axis represents the degree of departure ( ⁇ uv) from the black-body curve 400.
  • the target color points may be, e.g., 4000K, 3000K and 2700K on the black-body curve 400.
  • Other target CCTs or color points off of the black-body curve 400 may be used if desired.
  • Fig. 7 illustrates a predetermined tolerance for each of the target color points with a rectangle.
  • the CCT may vary by +90K, while at 3000K the CCT may vary by +55K, and at 2700K the CCT may vary by +50K.
  • These predefined tolerances for CCT are within a two step MacAdam ellipse centered on each respective target color point on the black-body curve.
  • the predetermined tolerance for the departure from the black-body curve ⁇ uv for each CCT is +0.001.
  • ⁇ uv may vary by a distance of 0.001 above the black- body curve 400 (expressed as a positive tolerance value, +0.001) and may vary by a distance of 0.001 below the black-body curve 400 (expressed as a negative tolerance value, -0.001).
  • This predetermined tolerance for ⁇ uv is within a one step MacAdam ellipse centered on each respective target color point on the black-body curve.
  • the predetermined tolerances for CCT and ⁇ uv illustrated in Fig. 7 is within a 2-step MacAdam ellipse and also within the tolerance of
  • the diagram illustrates two color lines centered on the 3000K CCT for reference purposes.
  • One color line 402 corresponds to the color point shift produced by a first wavelength converting material.
  • color line 402 is a yellow phosphor coating on the window 130.
  • Color line 404 corresponds to the color point shift produced by a second wavelength converting material.
  • color line 404 is a red phosphor coating on the sidewall insert 126.
  • Color line 402 indicates the direction of a shift in color point of light produced by the yellow phosphor.
  • Color line 404 indicates the direction of shift in color point produced by the red phosphor.
  • the first wavelength converting material and the second wavelength converting material are selected such that their respective directions of shift in color point are not parallel.
  • the direction of the color point shift of light emitted by LED module 100 can be arbitrarily designated. This may be achieved by selecting the proper thickness and/or concentration of each phosphor as discussed above.
  • the small spots, 412, 414, 416, and 418 graphically illustrate the color points produced by one LED module 100 using different wavelength converting components.
  • spot 412 illustrates the color point for the LED module 100 with one set of wavelength converting components.
  • the difference in the color points from spot 412 to 414 is parallel with the color line 402.
  • a different sidewall insert 126 is then selected to produce a color point illustrated by spot 416.
  • the difference in the color points from spot 414 to 416 is parallel with the color line 404. While this is within the 3000K target, an attempt to improve the color point by replacing the window 130 resulted in a color point illustrated by spot 418, where the shift between spot 416 and 418 is parallel with the color line 402.
  • By again replacing the window 130 a color point of the LED module 100 shifted along line 402 to produce a color point illustrated by large spot 420, which is well within the predetermined tolerance from the target color point of 3000K on the black-body curve.
  • the above example illustrates a trial and error approach to selecting the appropriate wavelength converting components for a particular set of LEDs 114 to produce an LED module 100 with a desired color point.
  • a trial and error approach it is unnecessary to measure the spectral power distribution of the light produced by the LEDs 114 before selecting the wavelength converting components.
  • a set of wavelength converting components may be selected and combined with the LEDs 114 and the resulting color point measured. Adjustments of the wavelength converting components may then be made based on the measured color point.
  • the spectral power distribution and/or color point of the LEDs 114 would be measured and the wavelength converting components may then be appropriately selected to produce the target color point within a predetermined tolerance.
  • the selection may be made based on, e.g., a database generated from previous trials or based on mathematical calculations. It may be desirable to measure the light output after the LEDs 114 are combined with the selected wavelength converting components to ensure the light is within the predetermined tolerance of the target color point, where one or both wavelength converting components may be changed if the light output is out of tolerance.
  • the LED module 100 can then be assembled (314).
  • the assembly may include permanently attaching the base 110 with the reflective plate 113, the top section 120 with sidewall insert 126 and the window 130, e.g., with bolts, screws, clamps, epoxy, silicon, or other appropriate attachment mechanisms.
  • a plurality of LED modules 100 may be produced with nearly identical color points, e.g., each LED module 100 may produce a color point that differs from another by a predetermined tolerance, e.g., a ⁇ uv of less than 0.001.
  • the LED module 100 includes a means for converting the spectral power distribution of the light emitting diodes to produce light from the light mixing chamber 101 with a color point within a degree of departure ⁇ u'v' of 0.009 or smaller from a target color point in a CIE 1976 u'v' diagram.
  • the means for converting the spectral power distribution includes a first means for converting the light produced by the light emitting diodes to produce a color point shift of a first magnitude along a first direction in the CIE 1976 u'v' diagram and a second means for converting the light produced by the light emitting diodes to produce a color point shift of a second magnitude along a second direction in the CIE 1976 u'v' diagram as illustrated in Fig. 4.
  • the first direction and the second direction are not parallel. Further, the first means and the second means are selectable to control their magnitudes in response to the spectral power distribution of the at least one light emitting diode to produce the desired color point within an acceptable degree of departure.
  • the first means and second means for converting the light produced by the light emitting diodes may be the two or more wavelength converting components having differing wavelength converting characteristics and may be, e.g., the reflective bottom surface 113, sidewall 128, or window 130 of the LED module. Alternatively, the first means and second means may be located at the same position, e.g., both wavelength converting components are on the window 130, sidewall 128 or bottom surface 113.
  • the wavelength converting components may be covered with or infused with wavelength converting materials, such as phosphor or luminescent dyes. Further, the wavelength converting components are selectable from a plurality of similar wavelength converting components that differ in the coverage areas, concentration, and thickness of the wavelength converting materials to produce different magnitudes in the color point shift in the CIE 1976 u'v' diagram.
  • the means for converting the spectral power distribution may also include a third or additional means for converting the light produced by the light emitting diodes that differs from the first means and the second means.
  • the means for converting the spectral power distribution may incorporate the first means and the second means into a single selectable component, e.g., the window 130, sidewall 128 or bottom surface 113.
  • the inventors have determined that when separate selectable components are used, e.g., a window 130 with a yellow phosphor and sidewall 128 with a red phosphor, approximately 10 different types of windows, i.e., 10 different wavelength converting characteristics, and 5 to 10 different types of sidewalls, i.e., 10 different wavelength converting characteristics, are generally adequate to produce the desired target color points with a small degree of departure, e.g., ⁇ u'v' of 0.009 or less. Accordingly, if the first means and second means are to be located in one selectable component, approximately 40 to 100 different selectable components would have to be produced and kept in inventory. Further, by separating the first means and second means, higher efficiencies and color rendering indices are achievable.
  • first means and second means may be separate, but pre-assembled into one selectable component, e.g., a window may be pre-assembled with a sidewall or bottom surface.
  • a window may be pre-assembled with a sidewall or bottom surface.
  • 40 to 100 different pre-assembled components would have to be produced and kept in inventory to achieve the same possible variation as using 10 types of a first means and 5- 10 types of a separately selectable second means.
  • Fig. 8 illustrates a set 500 of a plurality of LED modules 100a, 100b, 100c, and lOOd
  • each of the LED modules 100 in the set 500 uses wavelength converting components with different wavelength converting characteristics based on the spectral power distribution of the LEDs 114 in the LED modules 100.
  • the windows 130a, 130b, 130c, and 13Od, the sidewall inserts 126 (shown in Fig. 2) or the reflective plate (shown in Fig. 2) may have different wavelength converting characteristics as illustrated by the shading of windows 130a, 130b, 130c, and 13Od.
  • the LED modules 100a, 100b, 100c, and lOOd will produce light with color points that are difficult for a human observer to distinguish.
  • different wavelength LEDs 114 may be used in an LED module to improve the color rendering index (CRI).
  • CRI color rendering index
  • all the LEDs 114 in the LED module 100 have substantially the same peak wavelengths, e.g., all the LEDs 114 are from the same bin having a bin size of 5nm (for example a bin that includes 450nm to 455nm)
  • a CRI value between, e.g., 75-85 may be achieved for an LED module 100 with CCTs of 2700K, 3000K, and 4000K, when a yellow (YAG) phosphor is used on the window 130 and red phosphor with a peak wavelength of 630nm is used on the sidewall insert 126.
  • YAG yellow
  • red phosphor with a peak wavelength of 630nm is used on the sidewall insert 126.
  • Fig. 9 illustrates board 512 with a plurality of packaged LEDs 514 each having a peak wavelength of, e.g., 452nm and a second plurality of LEDs 515, each having a peak wavelength that is more than IOnm greater than the wavelength of LEDs 514.
  • the peak wavelength of the LEDs 515 may be between, e.g., 470nm and 5 IOnm.
  • the LEDs 515 are symmetrically arranged on the board 512 if possible.
  • the board 512 with LEDs 514 and 515 may be used in place of board 112 shown in Fig. 2. Compared to a board with LEDs that all have the same 452nm peak wavelength, board 512 achieves a higher CRI value.
  • an LED module 100 having a CCT of 2700K, 3000K or 4000K may use five LEDs 514 with a wavelength between 450nm and 455nm and three LEDs 515 with a wavelength of 500nm to 5 IOnm to achieve a CRI of 95.
  • the use of higher wavelength LEDs decreases efficiency, in terms of lumen out of the LED module divided by electrical power going in.
  • the number of LEDs 515 with different wavelengths and the particular wavelength of the LEDs 515 that are used is a balance of the target CRI value and the desired efficiency for the
  • phosphors may be used to produce high CRI values. A number of these phosphors are typically not used with LEDs due to the sensitivity of their respective emission properties to heat. However, the phosphors on the wavelength converting components, particularly the window 130 and the sidewall insert 126, are physically distant from the heat producing LEDs 114. In addition, the top section 120 of the LED module 100 is thermally coupled to the wavelength converting components and acts as a heat sink. Thus, the phosphors can be maintained at a relatively low temperature. For example, phosphors deposited directly on an LED source may reach temperatures in excess of 150 degrees centigrade, whereas the phosphors deposited on window 130 and sidewall insert 126 typically reach temperatures of approximately 70 to 90 degrees centigrade.
  • LED module 100 may be tailored to produce a desired CRI value.
  • phosphors such as La 3 Si 6 N 11 ICe 5 LaSi 3 N 55 (Sr 5 Ca)AlSiN 3 IEu 5 CaAlSiN 3 IEu 2+ , (Sr 5 Ca)AlSiN 3 :Eu 2+ 5 Ca 3 (Sc 5 Mg) 25 Si 3 0 12 :Ce 5 Sro 8 Ca o 2AlSiN 3 IEu 5 CaSc 2 O 4 ICe 5 (Sr 5 Ba) 2 SiO 4 IEu 2+ , SrGa 2 S 4 :Eu 2+ 5 SrSi 2 N 2 ⁇ 2 :Eu 2+ 5 Ca 3 Sc 2 Si 3 O 12 :Ce 3+ 5 Y 3 .

Abstract

L'invention porte sur un module de diode électroluminescente (100) fabriqué en utilisant au moins une diode électroluminescente (DEL) (114) et au moins deux composants sélectionnables qui forment ou font partie d'une chambre de mélange de lumière (101) qui entoure la ou les DEL et comprend un orifice de sortie. Un premier composant sélectionnable (130) comprend un premier type de matériau de conversion de longueur d'onde (132) ayant une première caractéristique de conversion de longueur d'onde et un second composant sélectionnable (126) comprend un second type de matériau de conversion de longueur d'onde (128) ayant une caractéristique de conversion de longueur d'onde différente. Les première et seconde caractéristiques de conversion de longueur d'onde modifient la distribution de puissance spectrale de la lumière produite par la DEL pour produire une lumière passant par l'orifice de sortie (122) qui a un point de couleur qui est dans une marge de tolérance prédéterminée (259) autour d'un point de couleur prédéterminé (257). En outre, un ensemble (500) de modules DEL peuvent être produits de telle manière que chaque module DEL a le même point de couleur dans les limites d'une tolérance prédéterminée. Le module DEL peut être produit par mesure préalable des caractéristiques de conversion de longueur d'onde des différents composants, et sélection de composants ayant des caractéristiques de conversion de longueur d'onde qui convertissent la distribution de puissance spectrale de la DEL en un point de couleur qui est dans une marge de tolérance prédéterminée autour d'un point de couleur prédéterminé.
PCT/US2009/064492 2008-11-21 2009-11-14 Module de diode électroluminescente à adaptation de couleur en trois parties WO2010059533A1 (fr)

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KR1020157033044A KR101645153B1 (ko) 2008-11-21 2009-11-14 3개의 칼러 매칭 부재를 갖는 ｌｅｄ 모듈
JP2011537525A JP5650655B2 (ja) 2008-11-21 2009-11-14 ３つの部分から成る色合わせ部を有する発光ダイオードモジュール
CA2743149A CA2743149C (fr) 2008-11-21 2009-11-14 Module de diode electroluminescente a adaptation de couleur en trois parties
KR1020147031873A KR20140148486A (ko) 2008-11-21 2009-11-14 3개의 컬러 매칭 부재를 갖는 ｌｅｄ 모듈
BRPI0916145A BRPI0916145A2 (pt) 2008-11-21 2009-11-14 método para produzir um módulo de diodos emissores de luz, módulo de iluminação e conjunto de módulos de diodo emissor de luz
MX2011005343A MX2011005343A (es) 2008-11-21 2009-11-14 Modulo de diodo emisor de luz con tres partes coincidentes de color.
EP09752701.4A EP2347454B1 (fr) 2008-11-21 2009-11-14 Module de diode électroluminescente à adaptation de couleur en trois parties
CN200980146272XA CN102217107A (zh) 2008-11-21 2009-11-14 具有三部分色调匹配的发光二极管模块

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US11706008P 2008-11-21 2008-11-21
US61/117,060 2008-11-21
US12/617,668 US8220971B2 (en) 2008-11-21 2009-11-12 Light emitting diode module with three part color matching
US12/617,668 2009-11-12

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JP (2) JP5650655B2 (fr)
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CN (1) CN102217107A (fr)
BR (1) BRPI0916145A2 (fr)
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