Optical device for producing high brightness light

An optical device is provided. The optical device comprises a light converting member arranged to at least party convert incoming light of a first wavelength into light of a second wavelength, to emit light of the second wavelength, and to reflect at least a part of the light of the first wavelength; and a light guide comprising a light entrance and a light exit, the light guide being arranged to guide incoming light of the first wavelength from the light entrance to the light converting member and to guide light emitted and/or reflected from the light converting member to the light exit. The light converting member and the light exit are at opposite surfaces of the light guide. The light converting member and the light exit are arranged along a main optical axis of the light guide, and the light entrance is arranged at a geometrical envelope surface surrounding the main optical axis of the light guide.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a § 371 application of International Application No. PCT/EP2016/060509 filed on May 11, 2016 and titled “AN OPTICAL DEVICE FOR PRODUCING HIGH BRIGHTNESS LIGHT,” which claims the benefit of European Patent Application No. 15169108.6 filed on May 26, 2015. International Application No. PCT/EP2016/060509 and European Patent Application No. 15169108.6 are incorporated herein.

FIELD OF THE INVENTION

The invention relates to an optical device for producing high brightness light. The present invention also relates to a lighting system comprising such an optical device.

BACKGROUND OF THE INVENTION

Illumination systems for generating high brightness illumination are interesting for various applications including spots, stage-lighting, headlamps and digital light projection.

High brightness light with a desirable spectral distribution may be obtained by a system1, seeFIG. 1, using a bright light source10such as a light emitting diode, LED, or a laser where a high intensity light beam of a first wavelength15(e.g. blue light) emitted by the light source is directed towards an optical device comprising a light converting member20placed on a static heat sink30. A dichroic reflector40is arranged to selectively reflect the light of the first wavelength15towards the optical device. Hence, the light converting member20is illuminated with a focused beam of light of the first wavelength15. Light of the first wavelength15is partially converted to light of a second wavelength25(e.g. yellow light) by the light converting member20. White light is obtained when light of the first and second wavelengths are mixed.

In such a setup, in order to achieve good heat dissipation from a phosphor light converting member combined with a high luminous efficiency, US20140166902A1 discloses a wavelength conversion body comprising a light guide body being monolithically connected to the phosphor body. Extending such construction for further improvement of heat dissipation, US20050270775A1 discloses a system, in so far similar to the one shown inFIG. 1, spatially separating the light source from the phosphor by a color separation element, as e.g. dichroic reflector40ofFIG. 1, for prohibiting converted light returning to the light source.

However, such dichroic reflector40reduces the intensity of the first light wavelength15emitted by the system. Moreover, the dichroic reflector also affects the color of the combined light. Furthermore, in the arrangement the lens35used for focusing and collecting the converted light25is not efficient enough to collect all the emitted light.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome at least some of the above problems, and to provide an optical device with improved light output.

According to a first aspect an optical device for producing high brightness light is provided. The optical device comprises a light converting member arranged to at least partly convert incoming light of a first wavelength into light of a second wavelength, to emit light of the second wavelength, and to reflect at least a part of the light of the first wavelength, and a light guide comprising a light entrance and a light exit, the light guide being arranged to guide incoming light of the first wavelength from the light entrance to the light converting member and to guide light emitted and/or reflected from the light converting member to the light exit. The light converting member and the light exit are arranged at opposite surfaces of the light guide.

The light converting member comprises a wavelength converting element. The wording wavelength converting element should be understood as any element that converts light of a first wavelength to light of a second wavelength. The wavelength conversion may be due to luminescence, fluorescence, and/or phosphorescence providing generation of a Stokes shift in the wavelength of the converted emitted light relative to the wavelength of the illuminating light.

The wording light guide should be understood as any element being arranged to guide light from one portion in space to another portion in space by preferably reflecting the light on surfaces of the light guide.

The light guide provides for both efficient in-coupling of the light of the first wavelength and concentrating the in-coupled light onto the light converting element. The light guide further provides for collimating outgoing light of the first and second wavelengths.

The light converting member and the light exit are arranged along a main optical axis of the light guide. The light entrance is arranged at a geometrical envelope surface surrounding the main optical axis of the light guide. Hence, the light of the first wavelength is coupled into the light guide from the side of the light guide.

By arranging the light entrance at the geometrical envelope surface surrounding the main optical axis of the light guide shadowing effects often arising when directing the light of the first wavelength towards the light converting member may be avoided.

The light entrance is separated from the light exit.

The light converting member may be arranged at a focal point of the light guide. By this the size of the light converting member and hence the optical device as a whole may be kept to a minimum. Further, the efficiency for wavelength conversion may be optimized.

The light converting member may be arranged at a point where the light concentration, i.e. power per surface area, is the highest within the light guide.

The light guide may have a parabolic shape. This provides for an efficient guidance of incoming light of the first wavelength towards the light converting member as well as for an efficient guidance of outgoing light of the first and second wavelengths from the light converting member. The parabolic shape of the light guide also provides for efficient collimation of the outgoing light.

The light guide may be a compound parabolic concentrator, CPC. Hence, heat produced in the light converting member may be efficiently transported away from the light converting member. This increases the efficiency of the light conversion in the light converting member. The CPC may be made of a highly heat conducting material. Examples of such material are yttrium aluminum garnet, YAG, sapphire or CaF2. Hence, a good heat management is achieved.

The light guide may be a parabolic reflector. The parabolic reflector may comprise a metal, a ceramic material or a glass material. The parabolic reflector may comprise a reflective surface comprising Al, Ag or a multilayer structure. It may also make use of total internal reflection (TIR). In the case the light guide is a parabolic reflector the optical device preferably also comprises a transparent heat conducting element arranged on top of the light converting member such that in-coming and out-going light to and from the light converting member may arrive and leave the light converting member and such that heat produced in the light converting member may be efficiently transported away from the light converting member. Hence, a good heat management is achieved.

The optical device may also comprise a reflective heat conducting element. The reflective heat conducting element may be arranged below the light converting member. By arranging elements working as heat sinks both on top and below the light converting member the efficiency of transporting heat away from the light converting member may be further improved. Hence, a good heat management is achieved.

The light entrance may comprise a mirror. Alternatively or in combination, the light entrance may comprise a diffraction grating. Efficient in-coupling of light into the light guide may then be achieved.

The light guide may comprise a plurality of light entrances. This may increase the power and light output. This may also improve the homogeneity of the beam profile of the outgoing light from the optical device.

According to a second aspect a lighting system is provided. The lighting system comprises an optical device according to the above, and a light source arranged to emit light of a first wavelength. The light source may be monochromatic. The light source may comprise a laser diode and/or a light emitting diode, LED. The light source may be a high intensity light source. The optical device is arranged to have high luminance. The luminance from the optical device is preferably more than 0.5 GCd/m2, more preferably more than 1 GCd/m2, and most preferably more than 3 GCd/m2.

The lighting system may further comprise an additional light guide arranged to guide light from the light source to the light entrance of the optical device. The additional light guide may e.g. be in the form of an optical fiber.

As illustrated in the figures, the sizes of layers and regions are exaggerated for illustrative purposes and, thus, are provided to illustrate the general structures of embodiments of the present invention. Like reference numerals refer to like elements throughout.

DETAILED DESCRIPTION

The light source210is arranged to emit light of a first wavelength. The light source210may be a monochromatic light source, for instance emitting blue light. The light source210may comprise a laser diode and/or a light emitting diode, LED. The light source210may be a high intensity light source. The luminance of the light source210is preferably more than 0.5 GCd/m2, more preferably more than 1 GCd/m2, and most preferably more than 3 GCd/m2.

Luminance from the optical device is preferably more than 0.5 GCd/m2, more preferably more than 1 GCd/m2, and most preferably more than 3 GCd/m2.

The optical device220comprises a light guide222comprising a light entrance223, a light exit224, and a light converting member226. The light entrance223is an interface between the light guide222and the surroundings, or environment, wherein light may be coupled into the light guide222. The light exit224is an interface between the light guide222and the surroundings, or environment, wherein light may be coupled out from the light guide222. The light converting member226and the light exit224are arranged along a main optical axis, OA, of the light guide222. The light entrance223is arranged at a geometrical envelope surface229(see alsoFIG. 3) surrounding the main optical axis OA of the light guide222. The light entrance223is physically separated from the light exit224.

The light entrance223may comprise a groove or opening in the light guide222. A mirror may be arranged at the light entrance223for coupling light into the light guide222. The mirror may be curved. The mirror surface may be coated with a dielectric or metallic reflective layer. Alternatively, or in combination a diffractive grating may be arranged at the light entrance223for coupling light into the light guide222. The diffractive grating may be curved.

The lighting system200is arranged such that the light source210emits the light of the first wavelength into the light guide222via the light entrance223. For this purpose a light source optical element230may be arranged downstream of the light source210to guide a beam of light of the first wavelength into the light entrance223. In this respect the wording downstream means a location in the beam of light emitted by a light source. Alternatively, instead of using the light source optical element230, the light of the first wavelength may be guided into the light entrance223by means of an additional light guide240, seeFIG. 3.

FIG. 3is illustrating an alternative embodiment of the lighting system wherein the light of the first wavelength emitted by the light source210is guided to the light entrance223by such an additional light guide240. As illustrated inFIG. 3the additional light guide240may be a separate element. Alternatively, the additional light guide240may be an integral part of the light guide222. In the latter case a virtual interface is obtained between the additional light guide240and the light guide222forming the light entrance223. The additional light guide240may e.g. be an optical fiber. Hence, light of the first wavelength emitted from the light source210may be guided into the light guide222via the additional light guide240. In all embodiments described above and below light of the first wavelength emitted from the light source210may be guided into the light guide222via the additional light guide240. The light beam at the light entrance223may be redirected towards the light converting member226by means of a reflective mirror or diffractive grating.

The light converting member226is arranged to at least partly convert incoming light of a first wavelength into light of a second wavelength. For instance, the light converting member226may be arranged to convert incoming blue light to yellow light. The light converting member226is further arranged to emit light of the second wavelength. The light converting member226is further arranged to reflect at least a part of the light of the first wavelength. Hence, the light converting member226may be referred to as a reflective light converting member. With reflective light converting member is meant a light converting member being arranged to be irradiated with light at the front surface thereof and to reflect at least a part of the incoming light. The light guide222preferably has a parabolic shape. However, other suitable shapes for guiding the light may also be used. The light converting member226may be arranged at a focal point of the light guide222.

The light guide222is arranged to guide incoming light of the first wavelength from the light entrance223to the light converting member226and to guide light emitted and/or reflected from the light converting member226to the light exit224. Hence, the light guide222is arranged to transmit light of the first and the second wavelengths.

The light converting member226comprises a wavelength converting element227and a reflective heat conducting element228. The wavelength converting element227is arranged to at least party convert incoming light of the first wavelength into light of the second wavelength. For instance, the wavelength converting element227may be arranged to convert incoming blue light to yellow light.

The wavelength converting element227is wedged in between the reflective heat conducting element228and the light guide222.

The wavelength converting element227may comprise a phosphor material such as a ceramic phosphor. The ceramic phosphor may be a Ce-doped YAG or LuAg ceramic such as Lumiramic with high thermal conductivity. The light converting member226may alternatively or also comprise organic fluorescent dyes or quantum dots.

Quantum dots are small crystals of semiconducting material generally having a width or diameter of only a few nanometers. When excited by incident light, a quantum dot emits light of a color determined by the size and material of the crystal. Light of a particular color can therefore be produced by adapting the size of the dots. Most known quantum dots with emission in the visible range are based on cadmium selenide (CdSe) with a shell such as cadmium sulfide (CdS) and zinc sulfide (ZnS). Cadmium free quantum dots such as indium phosphide (InP), and copper indium sulfide (CuInS2) and/or silver indium sulfide (AgInS2) can also be used. Quantum dots show very narrow emission bands and thus they show saturated colors. Furthermore the emission color can easily be tuned by adapting the size of the quantum dots. Any type of quantum dot known in the art may be used in the present invention. However, it may be preferred for reasons of environmental safety and concern to use cadmium-free quantum dots or at least quantum dots having a very low cadmium content.

The wavelength converting element227may in addition or alternatively comprise an inorganic phosphor. Examples of inorganic phosphor materials include, but are not limited to, cerium (Ce) doped YAG (Y3Al5O12) or LuAG (Lu3Al5O12). Ce doped YAG emits yellowish light, whereas Ce doped LuAG emits yellow-greenish light. Examples of other inorganic phosphors materials which emit red light may include, but are not limited to ECAS and BSSN; ECAS being Ca1-xAlSiN3:Euxwherein 0<x≤1, preferably 0<x≤0.2; and BSSN being Ba2-x-zMxSi5-yAlyN8-yOy:Euzwherein M represents Sr or Ca, 0≤x≤1, 0≤y≤4, and 0.0005≤z≤0.05, and preferably 0≤x≤0.2.

Hence, the luminescent material of the wavelength converting element227may essentially be made of material selected from the groups comprising (M<I>1-x-yM<II>xM<III>y)3(M<IV>1-zM<V>z)5O12, where M<I> is selected from the group comprising Y, Lu or mixtures thereof, M<II> is selected from the group comprising Gd, La, Yb or mixtures thereof, M<III> is selected from the group comprising Tb, Pr, Ce, Er, Nd, Eu or mixtures thereof, M<IV> is Al, M<V> is selected from the group comprising Ga, Sc or mixtures thereof, and 0≤x≤1, 0≤y≤0.1, 0≤z≤1, (M<I>1-x-yM<II>xM<III>y)2O3, where M<I> is selected from the group comprising Y, Lu or mixtures thereof, M<II> is selected from the group comprising Gd, La, Yb or mixtures thereof, M<III> is selected from the group comprising Tb, Pr, Ce, Er, Nd, Eu, Bi, Sb or mixtures thereof, and 0≤x≤1, 0≤y≤0.1, (M<I>1-x-yM<II>xM<III>y)S1-zSez, where M<I> is selected from the group comprising Ca, Sr, Mg, Ba or mixtures thereof, M<II> is selected from the group comprising Ce, Eu, Mn, Tb, Sm, Pr, Sb, Sn or mixtures thereof, M<III> is selected from the group comprising K, Na, Li, Rb, Zn or mixtures thereof, and 0≤x≤0.01, 0≤y≤0.05, 0≤z≤1, (M<I>1-x-yM<II>xM<III>y)O, where M<I> is selected from the group comprising Ca, Sr, Mg, Ba or mixtures thereof, M<II> is selected from the group comprising Ce, Eu, Mn, Tb, Sm, Pr or mixtures thereof, M<III> is selected from the group comprising K, Na, Li, Rb, Zn or mixtures thereof, and 0≤x≤0.1, 0≤y≤0.1, (M<I>2-xM<II>xM<III>2)O7, where M<I> is selected from the group comprising La, Y, Gd, Lu, Ba, Sr or mixtures thereof, M<II> is selected from the group comprising Eu, Tb, Pr, Ce, Nd, Sm, Tm or mixtures thereof, M<III> is selected from the group comprising Hf, Zr, Ti, Ta, Nb or mixtures thereof, and 0<=x<=1, (M<I>1-xM<II>xM<III>1-yM<IV>y)O3, where M<I> is selected from the group comprising Ba, Sr, Ca, La, Y, Gd, Lu or mixtures thereof, M<II> is selected from the group comprising Eu, Tb, Pr, Ce, Nd, Sm, Tm or mixtures thereof, M<III> is selected from the group comprising Hf, Zr, Ti, Ta, Nb or mixtures thereof, and M<IV> is selected from the group comprising Al, Ga, Sc, Si or mixtures thereof, and 0≤x≤0.1, 0≤y≤0.1, or mixtures thereof.

Particularly suitable luminescent materials of the wavelength converting element227are Ce doped Yttrium aluminum garnet (YAG, Y3Al5O12) and/or Lutetium-Aluminum-Garnet (LuAG).

Thermal conductivity of the wavelength converting element227is preferably higher than 2 W·m−1·K−1, more preferably higher than 6 W·m−1·K−1, and most preferably higher than 20 W·m−1·K−1.

The wavelength converting element227is preferably of the same size as the spot of light of the first wavelength. Typical sizes are 200 μm, 400 μm, and 600 μm in diameter.

The wavelength converting element227is in direct thermal contact with the reflective heat conducting element228. The wavelength converting element227may be chemically bonded to the reflective heat conducting element228. Hence, no organic glue or other material which burns in a high intensity light spot is needed.

The wavelength converting element227comprises a front surface arranged to face the light guide222. The wavelength converting element227comprises a back surface, the back surface being opposite the front surface. The reflective heat conducting element228is arranged at the back surface of the wavelength converting element227.

The reflective heat conducting element228comprises a reflecting surface. The reflective heat conducting element228is arranged to reflect light of the first wavelength. The reflective heat conducting element228is arranged to reflect light of the second wavelength. The reflective heat conducting element228may comprise a diffraction grating, a mirror or other suitable reflector. Efficient redistributing of light is thereby achieved and the light emission from the optical device220is greatly increased.

The reflective heat conducting element228is further arranged to distribute heat produced in the wavelength converting element227. The reflective heat conducting element228may comprise a material chosen from the group of materials comprising silver; aluminum; boron nitride; microcellular formed polyethylene terephthalate, MCPET; translucent polycrystalline alumina ceramics, PCA; titanium oxide, TiO2; or a combinations thereof. The reflective heat conducting element228may comprise a specular or diffuse reflecting material such as aluminum or silver. The reflecting element may also comprise boron nitride or aluminum oxide providing reflection and improved thermal conductivity for improved thermal management. Thermal conductivity of the reflective heat conducting element228is preferably higher than 2 W·m−1·K−1, more preferably higher than 6 W·m−1·K−1, and most preferably higher than 20 W·m−1·K−1. The wavelength converting element227is in thermal contact with the reflective heat conducting element228.

The wavelength converting element227may be in direct thermal contact with the reflective heat conducting element228. This may be achieved by chemically bonding the wavelength converting element227to the reflective heat conducting element228. Hence, no organic glue or other material which burns in a high intensity light spot is needed. Efficient redistributing and emission of heat is thereby achieved and the light emission from the lighting system200may be increased. This will reduce the heat load on the wavelength converting element227. Quantum efficiency of the wavelength converting element227is thus increased.

According to the embodiments ofFIGS. 2, 3 and 4the light guide222is a compound parabolic concentrator, CPC. The CPC is a solid body. The wavelength converting element227is in direct thermal contact with the light guide222in the form of the CPC.

The CPC comprises material with high heat conductivity. Hence, the CPC is arranged to distribute heat produced in the wavelength converting element227. This will reduce the heat load on the wavelength converting element227. Quantum efficiency of the wavelength converting element227is thus increased. Efficient redistributing and emission of heat is thereby achieved and the light emission from the lighting system200may be increased.

The wavelength converting element227may be chemically bonded to the CPC. Hence, no organic glue or other material which burns in a high intensity light spot is needed. Alternatively, the wavelength converting element227may be embedded in the CPC. By embedding the wavelength converting element227in the CPC, the heat conductivity away from the wavelength converting element227may be enhanced. Further this also enables side cooling of the wavelength converting element227.

Thermal conductivity of the CPC is preferably higher than 2 W·m−1·K−1, more preferably higher than 6 W·m−1·K−1, and most preferably higher than 20 W·m−1·K−1.

The CPC may be made of ceramic material, CaF, Al2O3, diamond and/or glass. As mentioned above the wavelength converting element227may comprise a doped portion of a ceramic material, e.g. yttrium aluminum garnet, YAG or lutetium aluminum garnet, LuAG. If so, the CPC is preferably YAG or LuAG, respectively.

The lighting system200may further comprise an optical element250arranged to collect the light emitted from the optical device220. The optical element250is inFIG. 2illustrated as a lens but the skilled person in the art realizes that other lenses or mirrors and lens or mirror systems may be used. For example the optical element250may be formed as an integral part of the light guide222.

The optical element250may further be arranged to focus the collected light into a mixing element260. The mixing element260is arranged to mix light entering the mixing element260. The light entering the mixing element260originates from the optical device220and may comprise a spatially varying spectral composition, i.e. light of the first and the second wavelength may be separated in space. The light that enters the mixing element260is mixed spatially by for instance multiple reflections and/or diffraction. Light leaving the mixing element260may thereby have a spatially more uniform spectral distribution than the light entering the mixing element260. A lighting system200providing a spatially more uniform output of light may thereby be obtained. The mixing element260may be an optical fiber or a light guide. The optical function of the mixing element260may be transportation of the light beam to another location.

As mentioned above, the light of the first wavelength may be blue light and the light of the second wavelength may have a longer wavelength than the first wavelength, such as yellow light. A combination of the blue and the yellow light may produce white light. By mixing the blue and the yellow light with the mixing element260the lighting system200may provide white light with a more uniform spectral distribution.

The mixing element260may be an optical fiber. A simple, cost effective and flexible mixing element260may thereby be achieved. The light entering the mixing element260may further propagate efficiently in the core of the optical fiber by total internal reflection. The mixing element260may alternatively be a transparent rod. The cross-section of the rod or the optical fiber may be non-circular, for instance having a square, hexagonal or octagonal cross-section in order to improve light mixing.

The reflective heat conducting element228may be in direct thermal contact with the light guide222. This will enhance the heat conductivity away from the wavelength converting element227being wedged in between the reflective heat conducting element228and the light guide222.

The wavelength converting element227and the CPC may be sintered into a single element.

The reflective heat conducting element228and the CPC may be made of a similar material.

As illustrated inFIG. 4the light guide222may comprise a plurality of light entrances223receiving light from a plurality of light sources210. This may increase the power and light output of the lighting system. This may also improve the homogeneity of the beam profile of the outgoing light from the optical device.

In the embodiments discussed above in connection withFIGS. 2-4the light guide222was in the form of a CPC. However, instead of using a CPC it is also possible to use a parabolic reflector. This is illustrated inFIG. 5. In all embodiments described above and below a light guide in the form of a parabolic reflector may be used instead for the CPC. The parabolic reflector comprises a metal, a ceramic material or a glass material. The parabolic reflector further comprises a reflective surface comprising Al, Ag or a multilayer structure. It may also make use of total internal reflection, TIR. Further, using a parabolic reflector a transparent heat conducting element229may be arranged on top of the wavelength converting element227. This will enhance the heat conductivity away from the wavelength converting element227being wedged in between the reflective heat conducting element228and the transparent heat conducting element229.

Furthermore, the light entrance may be arranged at the same surface of the light guide as the light exit. Hence, according to this embodiment the light entrance is arranged at the opposite surface of the light guide as compared to the light converting member. The incoming light of the first wavelength may according to this embodiment be coupled into the light guide via a diffractive grating. The diffractive grating may be arranged such that it diffracts the light of the first wavelength. The diffractive grating may be arranged such that it substantially does not affect the propagation of light of the second wavelength.