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    Light Scattering by Controlled Porosity in Optical

    Uploaded by

    kinosraj kumaran

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    ca) United States Patent (10) Patent No: US 8,728,835 B2 Boerkekamp et al. (4s) Date of Patent: May 20, 2014 (s8) LIGHTSCATTERING BY CONTROLLED 2) Us. POROSITY IN OPTICAL CERAMICS FOR crc Hon. 34502 (201301) LED USPC 438/29 “ : ($8) Field of Clastation Search 5) Inventors: Jacobus Gerardus Boerkekamp, sas Eindhoven (NL); Oliver Steigelmann, cre HOLL 33/502 Eindhoven (NL); Henricus Albertus USPC 438/29 ‘Maria Van Hal, Vessem (NL); Johannes ‘See application file for complete search history, Francincs Mari Cilleen, Eindhoven a} 66 References Cited (73) Assignee: Koninklijke Philips N.V., Eindhoven US. PATENT DOCUMENTS (Ly 6,973,825 B2 8/2004. Pickrell etal. ©) Novice . S7o198 BL Sabot Strela (*) Note: Subject ny disclaimer, thetem ofthis yg 22 BI 23K Sen eta Daten ib exended or ajusted under 35. UBOWPIRE AL, 402002 Dich a USC. 1846) by 481 days ondniow> Al ‘62001 Shang dal imngolsssos AL 72004 Ross ea (2) AppLNos Tawa Soistior al 83008 Mauyanastal (22) PCTFited: — Jan,9, 2009 FOREIGN PATENT DOCUMENTS (86) PCTNos —PCTIR2009/0S0086 ra 1s9s457 al 142005 Wo zoos AL ‘Danes e710, Wo ons AL anor (2),(4) Date: Jul. 7, 2010 wo 2oon1o7917 82972007 (87) PCT Pub. Nos WO2009/090580 Samad PCT Pb. Dat: Jul 23,2009 Primary Examiner — William D Coleman «) Prior Publication Data @ ABSTRACT US2O0DT6N17 AL Now 4, 2010 The present iavenion lates to ight ening device (100) comprising test one ight emiting diode (101) anc at east 0) Foreign Application Priority Data One porous ceramic element (102), which ceramic element (G02) is arranged to receive light from the light eiting Jan. 15,2008 (EP) 08150250. diode( (01). The present invention also relates o methods forthe manlfeure of the Fight ening doves (100 and of )) ma, the pos craic element 102), Hoi 3100 (200601) moi 3450 (201001) 12 Claims, 3 Drawing Sheets 100 104 102 s ye oh, 103 107 US. Patent May 20, 2014 Sheet 1 of 3 US 8,728,835 B2 100 104 fo Se eee So gt epee et N 103 101 FIG, 1 4 0.45 -90 60-30 0 30 60 90 "99 -60 -30 0 30 60 90 Angle (°) Angle (°) FIG. 2a FIG. 2b US. Patent May 20, 2014 Sheet 2 of 3 US 8,728,835 B2 HN ‘Thermal treatment FIG. 3 FIG. 4a FIG. 4b US. Patent May 20, 2014 Sheet 3 of 3 US 8,728,835 B2 Porosity O4Anwoaae 0 5 10 15 Polymeric particles (vol%) FIG. 5a 65.0 }- 62.5 F 60.0 87.5 55.0 k: 0 5 10 15 Polymeric particles (vol%) FIG. 5b US 8,728,835 B2 1 LIGHT SCATTERING BY CONTROLLED. POROSITY IN OPTICAL CERAMICS FOR LEDS ‘TECHNICAL FIELD ‘The present invention relates toa light emiting device ‘comprising at leat one light emitting diode and at least one porous ceramie element comprising at last one wavelength ‘converting materia, said ceramic element being arranged to receive light Som said light emitting diode; and vo a method forthe manufacture of the device and the porous ceramic clement BACKGROUND OF THE INVENTION Semiconductor light eniting devices comprising Hight ‘emitting diodes (LEDs) are amoag the most efficient and robs light sources currently available Iluminationrequies. ‘white color light sources in particular white light sources of| high colar rendering properties. Various attempts have been ‘made to make white light emitting illumination systems by using LEDs as ration sources, ‘One method of obtaining white ight isto use blue LEDs and convert part of the emitted light to yellow light (wave- length spectrum at bout S80 nm) via wavelength converting materials, suchas for example modified YAG:Ce based phos- phors. Since yellow light stimulates the red and greea cep torsoftheeye the resulting mix of blueand yellow light gives, the appearane of white ‘Typically. this is done by arranging a phosphor-containing material, i. a wavelength converting material on the LED such that part o the ight emitted by the LED is absorbed by the phosphors ands emittedas Fghiof wavelength diferent fiom that ofthe absorbed light, However, one problem associated ith such an arrange: meat isthe color homogeneity of the light provided. The ‘conversion strength ofthe wavelength converting material is ‘controled by the activator content eg. Ceas in AG: Ce) and the path length of the blue ight which travels through the ‘ceramic element. This paths dependent on the thickoess ad scattering of the wavelength converting mera. Typically, the ceramic element guides the blue light towards the edges, Since inthis diretion the pathlength is much loager than if the light emerges ina vertical direction higher conversion ratio i obiained and this results inthe fommation of aso called “yellow ring” whea looking at larger angles. Tn order to solve he problem of the formation of a yellow ring and to obtain homogenous color impression, scattering rust be introduced ia the ceramic element. WO 2006007876 describes the use of « phosphor in polyerystaline ceramic structure and a light-emitting oe ‘ment provided with the same comprising an LED in which a ‘composite stucture of phosphor particles is embedded in a matrix comprising a polycrystalline cera alain, ‘WO 2006/007876 states that color homogencity may be achieved by introducing pores and second phases that intro- ‘duce light scattering. The porosity should wot exceed 1% and the pore sizes should be kept small, eg smaller than 300 nm, preferably below $0 nm. In ceramics, porosity is conventionally obtained by stop- ping sintering in an intermediate stage ofthe process in ordet to avoid the formation of stable, fully densified ceramic body. Inherent to such a process the conto of a specific porosity levels diliultasa smalltemperature difference can ‘cause large density (and porosity) variations having conse- 2 «quences forcolor conversion stength and thuscolorhomoge- nity, Such ceramic elements ar inappropriate for mass pro= dvetion, Hence, there isa nood in the art to provide a light emitting device which prevents the formation ofa yellow ring around the device, and which allows fora more contelled and robust processto achieve the desired porosity during manuturing, the device being eay and inexpensive to manufacture alw= ing for mass production ‘SUMMARY OF THE INVENTION ‘One objectof the present inventonisto atleast partly fill the above mentioned need and t provide a light emiting device that emits ight with high color homogeneity, espe- cially where the ou-couplingo ight resulting inthe forma- tion of a yellow ring around the light emiting device is avoided Another object ofthe present invention isto provide such a light emitting device, which easy and inexpensive to man- ‘goture thereby enabling mss prodvetion of such ight emit- ting devices. ‘These and other objects of the presen invention are achieved by a light-emitting device and methods for their prodvetion according tothe appended claims, Ths, in fst aspect the present invention relates 10a ligh-emiting device comprising atleast one light emitting diode and atleast one porous ceramic element, The porous ceramic element comprises at least one wavelength convet- ing material and is aranged to receive ight om the ight emitting diode() The ceramic element hasan average pore diameter of fom 2 ym to 10pm, Ina device ofthe preset iavestin, ight thats emited by the LED at obligue angles will enter the porous ceramic element and be seatered by the pores provided therein. The pores funtion as seatering centers, and as a result blue Primary radiation and yellow secondary radiation are mixed homogenous. Hence, a homogenous color impression is bined, andthe fomationofa yellow ringat the elgsothe device is prevented. An average pore diameter range of from 2m to 10 pm provides the desired catering, thereby resulting in. homoge enous light emission. Another advantage with this average pore diameter range is that a controlled porosity may be obtained daring te sintering stage ofthe manwfacturing pro- cess. Usually tis is critical tp, sine smaller pres than those ofthe described range are ffiult to maintain a the ceramic ody afer sintering Inembodiments ofthe invention, the ceramic element is formed from ceramic panicles havingan average patclesize of Sy to 10 ym. For ceramic elements formed from ceramie particles hav- ing the above mentioned particle size, the average por diam- eters preferably higher than 2 ym, This is due to the fct that the maintenance of porosity during sintering is dfficult and troublesome since pores smaller than about 2 jm are dificult to maintain. On the other hand, if the average diameter exooeds 10 jum a large depres of ligt is setter ina back- ‘wards direction, i. toward the ight emiting diodes) such thatthe light output efiiency’is redced Hence. the pore averae diameter of from 2 yum to 10 um secoring tothe preset inveation provides fora compromise between the color homogeneity achieved and the light eff- ciency which is reduced due to backscattering “The scattering obtained with pores ofthe above mentioned average diameter range results in an enhanced conversion of US 8,728,835 B2 3 blue fight ato yellow light such that color homogeneity over angle and light emission efficacy isl uficen Preferably the pore diameter of said ceramic element is from 2m Sum, Within thisrange, te lght loss dueto back scattering i further reduced. Inone embodiment ofthe present invention, the porosity of. the ceramic element isin the range of from 1.5 to 5% by volume. A porosity within this range may be easily obtained during manufacturing and remains constant during final stage sintering. Furermor, 2 porosity interval of from 1.5 to 5% results the desired seatering andthe prevention ofa yellow ring around the High emiting device Tha second aspect, the present invention relates to amethod for auanufaturing alight emitting device comprising: providing a slury comprising ceramic particles of at least ‘one wavelength converting material and polymer par- ticles having a diameter of from 2 ym to 10 wm; forming a ceramic body fom said sury: reawwving sid polymeric particles fom said ceramic body to provide a porous ceramic element having an average pore diameter of from 2 ym to 10 ums and ‘arranging said porous ceramic elemeat to receive light fom at least one light emitting diode ‘The method according othe invention is easy to cary out, and inexpensive, thereby enabling mass prection of Fight, ‘emitting devices. An important advantage with the method according to the invention is that it tagets the desired scattering by controling the ponssity of the sintered ceramic body. Accordingly, ‘conirolled porosity can be achieved by final stage sintering avoiding the aecesity to use partial sintering. “The method according tothe invention makesis pssibleto ‘exociy steer the porosity and seater tothe amount quire. In embodiments of the invention, the ceramic particles have an average particle size of fom 5 mo 10 um. Ina preferred embodiment ofthe invention, te polymeric panicles have an average pore diameter of from 2 jum oS wm, providing poresin the ceramic elemeat having essentially the same average diameter Within this ange, ls ight is lost due to back seattering, In embodiments, the polymeric particles comprise e.g. polystyrene or polyacrylate, Such polymers ean be easly

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