Today, freeform micro-optical structures are desired components in many photonic and optical applications, such as lighting and detection systems, due to their compactness, ease of system integration, and superior optical performance. The high complexity of a freeform structure’s arbitrary surface profile and the need for high throughput upon fabrication require sophisticated approaches for their integration into a manufacturing process. In this paper, we discuss a smart fabrication process of freeform micro-optical elements that ranges from their design by optical simulations to their cost-efficient fabrication by maskless laser direct write lithography (MALA) and replication from the as-fabricated master by imprinting. Aided by profilometry and optical microscopy, the fidelity of the fabricated freeform micro-optical elements to the design is characterized. Finally, the light intensity distribution on a target plane affected by the freeform micro-optical element illuminated with a light-emitting diode is determined and compared with the predicted one.
Today, freeform micro-optical structures are desired components in many photonic and optical applications such as lighting and detection systems due to their compactness, ease of system integration and superior optical performance. The high complexity of a freeform structure’s arbitrary surface profile and the need for high throughput upon fabrication require novel approaches for their integration into a manufacturing process. For the fabrication of polymer freeform optics, in this contribution we discuss two principal technologies, mask-less laser direct write lithography (MALA) and replication from the as-fabricated master by imprinting. We show the high flexibility in design and rapid-prototyping of freeform optical microstructures that can be achieved by such an approach. First, the original structures known as masters are fabricated using MALA. Because of the specific requirements on shape and height (>50μm) of the microstructures, laser writing and photoresist processing have to be performed within a narrow range of fabrication parameters. Subsequently, UV-soft lithography based replication is used for serial production of the freeform micro-optical elements within a batch process. Aided by profilometry, optical microscopy and atomic force microscopy, the fidelity of the fabricated freeform microoptical elements to the design is characterised. Finally, the light intensity distribution on a target plane caused by the freeform micro-optical element illuminated with an LED is determined and compared with the predicted one.
State of the art fabrication of LED modules based on chip-on-board (COB) technology comprises some shortcomings
both with respect to the manufacturing process itself but also with regard to potential sources of failures and
manufacturing impreciseness. One promising alternative is additive manufacturing, a technology which has gained a lot
of attention during the last years due to its materials and cost saving capabilities. Especially direct-write technologies like
Aerosol jet printing have demonstrated advantages compared to other technological approaches when printing high
precision layers or high precision electronic circuits on substrates which, as an additional advantage, also can be flexible
and 3D shaped. Based on test samples and test structures manufactured by Aerosol jet printing technology, in this
context we discuss the potentials of additive manufacturing in various aspects of LED module fabrication, ranging from
the deposition of the die-attach material, wire bond replacement by printed electrical connects as well as aspects of high-precision
phosphor layer deposition for color conversion and white light generation.
Common direct-lit systems for general lighting applications are using LEDs as light sources, which are placed in a
certain distance in a regularly arranged array. In order to achieve a homogenous light distribution a diffuser sheet has to
be placed on the out-coupling side in a certain height above the LED array. The position of the diffuser sheet is strongly
correlated to the distance between the LEDs and is responsible for the positional homogenization of the LED spots,
while the rough side of the diffuser averages the angular light distribution. In order to maintain the uniformity of the
luminance the distance of the LEDs compared to the height of the diffuser sheet placement (DHR ratio) is of relevance.
DHR values of 1 are hardly achievable. To overcome this limitation additional optical elements like freeform lenses are
necessary.
In this contribution we discuss a smart design concept for an extremely flat direct-lit lighting system. It is characterized
by an improved distance (LEDs) to height (diffuser sheet) ratio compared to diffuser sheet only-approaches and a
smaller thickness compared to common freeform approaches. For this demand we designed very thin freeform lenses
with a maximal height of 75 μm that allow to maintain a uniform illumination in a flat direct-lit backlight using an LEDarray
with a comparably large distance between the individual LEDs. The concept emphasizes the use of maskless laser
direct write lithography for the cost-effective fabrication of the thin freeform micro-lens array.
Typically, light emission from light-emitting diodes (LEDs) occurs under a broad range of angles. On the other hand, for a lot of applications a more directed light emission is desired. This can be realized with the use of additional optical elements, like lenses. Still, this may provide some complications in case of light sources consisting of a plurality of individual LEDs, e.g., a panel light, which is expected to illuminate a target area homogenously. Instead of a homogeneous illumination, the use of lenses is prone to give reason for an inhomogeneous light distribution in which the emission from the individual LEDs is easily distinguishable. Therefore, there is a strong request for alternative strategies of beam shaping of LED light in LED-luminaires targeting both on a directed as well as homogeneous illumination of an area. In this contribution we discuss an alternative approach in this regard: Firstly, a collimator is designed, which strongly directs the light emitted from a single LED light source. Subsequently, a foil with an optical structure, that can be fabricated in a cost-effective way by soft-lithography and which diffuses the collimated light again, is applied on the collimator. The optical structure and the respective amount of light diffusion are designed in a way that the desired radiation patterns both from a single as well as a plurality of LED sources can be realized. In addition, we show that the realization of a desired radiation profile is not the only advantage of such an approach. A key benefit of this concept is the possibility to reduce the angle dependent inhomogeneity
For a systematic approach to improve the white light quality of phosphor converted light-emitting diodes (LEDs) for general lighting applications it is imperative to get the individual sources of error for color temperature reproducibility under control. In this regard, it is imperative to understand how compositional, optical and materials properties of the color conversion element (CCE), which typically consists of phosphor particles embedded in a transparent matrix material, affect the constancy of a desired color temperature of a white LED source. In this contribution we use an LED assembly consisting of an LED die mounted on a printed circuit board (PCB) by chip-on-board technology and a CCE with a glob-top configuration as a model system and discuss the impact of potential sources for color temperature deviation among individual devices. Parameters that are investigated include imprecisions in the amount of materials deposition, deviations from the target value for the phosphor concentration in the matrix material, deviations from the target value for the particle sizes of the phosphor material, deviations from the target values for the refractive indexes of phosphor and matrix material as well as deviations from the reflectivity of the substrate surface. From these studies, some general conclusions can be drawn which of these parameters have the largest impact on color deviation and have to be controlled most precisely in a fabrication process in regard of color temperature reproducibility among individual white LED sources.
Optical and photonic devices often comprise optical elements which interact with light on different geometric length scales, ranging from (sub-)wavelength to several millimetres. Well-established physical models exist to describe coherent or incoherent effects, like refraction or diffraction including polarization effects, which form the basis for several simulation approaches. While at dimensions much larger than the light wavelength the incoherent ray-tracing (RT) techniques are commonly used, at dimensions in the (sub)-wavelength regime simulation tools like the Finite- Difference Time-Domain (FDTD) method are indispensable, as they allow for the simulation of coherence effects where phase relations play a crucial role. The two approaches are structurally entirely different, so that a proper description for the macroscopic and the (sub-)wavelength scale at once would only work by connecting the two approaches together, exploiting the best of both in a step-by-step simulation. In this contribution, the applicability of an interface procedure for combined ray-tracing and FDTD simulations of optical systems which contain two diffractive gratings is discussed. Suchlike systems require multiple FDTD↔RT steps for a complete simulation. For minimizing the error due to the loss of the phase information in an FDTD→RT step, we use a recently derived equation for calculating the maximal coherence correlation function (MCCF) to estimate the minimum distance between the different grating structures. In addition a waveguide system comprising two coupling grating structures is investigated with the MCCF and simulated using the simulation approach. As a consequence of the waveguide setup multiple FDTD↔RT steps in an iterative manner are necessary; the corresponding results are discussed.
For a systematic approach to improve the white light quality of phosphor converted light-emitting diodes (LEDs) for general lighting applications it is imperative to get the individual sources of error for correlated color temperature (CCT) reproducibility and maintenance under control. In this regard, it is of essential importance to understand how geometrical, optical and thermal properties of the color conversion elements (CCE), which typically consist of phosphor particles embedded in a transparent matrix material, affect the constancy of a desired CCT value. In this contribution we use an LED assembly consisting of an LED die mounted on a printed circuit board by chip-on-board technology and a CCE with a glob-top configuration on the top of it as a model system and discuss the impact of the CCE shape and size on CCT constancy with respect to substrate reflectivity and thermal load of the CCEs. From these studies, some general conclusions for improved glob-top design can be drawn.
Color temperature constancy and color temperature maintenance are key issues in the context of the utilization of light-emitting diodes (LEDs) for general lighting applications. For a systematic improvement, it is imperative to understand how compositional, optical and thermal properties of the color conversion elements (CCE), which typically consist of phosphor particles embedded in a transparent matrix material, affect the constancy of a desired color temperature of a white LED source under operation. In particular, thermal stress, like a distinct thermal load of the CCEs under operation may also cause notable color shifts. In order to gain a better understanding of the thermal behavior of CCEs under operation, in this contribution we give by means of a combined optical and thermal simulation procedure a comprehensive discussion on the impact of different CCE shapes and sizes on their thermal responses.
Ferroelectric material supports both pyro- and piezoelectric effects that can be used for sensing pressures on large, bended surfaces. We present PyzoFlex, a pressure-sensing input device that is based on a ferroelectric material (PVDF:TrFE). It is constructed by a sandwich structure of four layers that can easily be printed on any substrate. The PyzoFlex foil is sensitive to pressure- and temperature changes, bendable, energy-efficient, and it can easily be produced by a screen-printing routine. Even a hovering input-mode is feasible due to its pyroelectric effect. In this paper, we introduce this novel, fully printed input technology and discuss its benefits and limitations.
Optimizing the properties of optical and photonic devices calls for the need to control and manipulate light within
structures of different length scales, ranging from sub-wavelength to macroscopic dimensions. Working at different
length scales, however, requires different simulation approaches, which have to account properly for various effects such
as polarization, interference, or diffraction: at dimensions much larger than the wavelength of light common ray-tracing
techniques are conveniently employed, while in the (sub-)wavelength regime more sophisticated approaches, like the socalled
finite-difference time-domain (FDTD) technique, are used.
Describing light propagation both in the (sub-)wavelength regime as well as on macroscopic length scales can only be
achieved by bridging between these two approaches. Unfortunately, there are no well-defined criteria for a switching
from one method to the other, and the development of appropriate selection criteria is a major issue to avoid a
summation of errors. Moreover, since the output parameters of one simulation method provide the input parameters for
the other one, they have to be chosen carefully to ensure mathematical and physical consistency.
In this contribution we present an approach to combine classical ray-tracing with FDTD simulations. This enables a joint
simulation of both, the macro- and the microscale which refer either to the incoherent or the coherent effects,
respectively. By means of an example containing one diffractive optical element (DOE) and macroscopic elements we
will show the basic principles of this approach and the simulation criteria. In order to prove the physical correctness of
our simulation approach, the simulation results will be compared with real measurements of the simulated device. In
addition, we will discuss the creation of models in FDTD based on different analyze techniques to determine the
dimensions of the DOE, as well as the impact of deviations between these different FDTD models on the simulation
results.
For a systematic approach to improve the white light quality of phosphor converted light-emitting diodes (LEDs) for
general lighting applications it is imperative to get the sources of error for color constancy under control. In this context,
it is essential to gain a deeper insight how the individual components of an LED package may contribute to color
deviation. Typically, both monochromatic and phosphor converted light-emitting diodes are finally encapsulated by a
pristine silicone layer in order to prevent mechanical damage of the LED packages. In this contribution we focus on the
shapes of such encapsulation layers and discuss, based on an optical simulation procedure, their impact on the color
temperatures of phosphor converted white LEDs as well as the ramifications of manufacturing imprecision of these
shapes on the constancy and reproducibility of a desired color temperature.
Color constancy and color maintenance are key issues in the context of the utilization of light-emitting diodes (LEDs) for general lighting applications. For a systematic approach to improve the white light quality of phosphor converted LEDs and to fulfill the demands for color temperature reproducibility and constancy, it is imperative to understand how compositional, optical and thermal properties of the color conversion elements (CCE), which typically consist of a
phosphor particles embedded in a transparent matrix material, affect the correlated color temperature of a white LED
source. Based on a combined optical and thermal simulation procedure, in this contribution we give a comprehensive
discussion on the underlying coherences of light absorption, quantum efficiency and thermal conductivity and deduce
some strategies to minimize the temperature increase within the CCE in order to maintain acceptable color variations
upon device operation.
The development of photonic devices with tailor-made optical properties requires the control and the manipulation of
light propagation within structures of different length scales, ranging from sub-wavelength to macroscopic dimensions.
However, optical simulation at different length scales necessitates the combination of different simulation methods,
which have to account properly for various effects such as polarization, interference, or diffraction: At dimensions much
larger than the wavelength of light common ray-tracing (RT) techniques are conveniently employed, while in the subwavelength
regime more sophisticated approaches, like the so-called finite-difference time-domain (FDTD) technique,
are needed. Describing light propagation both in the sub-wavelength regime as well as at macroscopic length scales can
only be achieved by bridging between these two approaches.
In this contribution we present on the one hand a study aiming at the determination of the intermediate size range for
which both simulation methods are applicable and on the other hand an approach for combining classical ray-tracing
with FDTD simulation in order to handle optical elements of large sizes. Generally, the interface between RT and FDTD
is restricted to very small sample areas. Nevertheless, many real world optical devices use e.g. diffractive optical
elements (DOEs) having comparably large areas in the order of 1-2 mm² (or larger). Therefore, one has to develop
strategies in order to handle the data transfer between FDTD and RT also for structures of such larger size scales. Our
approach in this regard is based on the symmetries of the structures. In this way support programs like e.g. MATLAB
can be used to replicate the near-field of a single structure and to merge it to the near-field of a larger area. Comparisons
of RT and FDTD simulations in the far-field can be used to validate the physical correctness of this approach. With such
procedure it is possible to optimize light propagation effects at both the macro- and microscale and to exploit their whole
potential for the manipulation and optimization of optical and photonic devices.
We demonstrate the printing of a complex smart integrated system using only five functional inks: the fluoropolymer
P(VDF:TrFE) (Poly(vinylidene fluoride trifluoroethylene) sensor ink, the conductive polymer PEDOT:PSS (poly(3,4
ethylenedioxythiophene):poly(styrene sulfonic acid) ink, a conductive carbon paste, a polymeric electrolyte and SU8 for
separation. The result is a touchless human-machine interface, including piezo- and pyroelectric sensor pixels (sensitive
to pressure changes and impinging infrared light), transistors for impedance matching and signal conditioning, and an
electrochromic display. Applications may not only emerge in human-machine interfaces, but also in transient
temperature or pressure sensing used in safety technology, in artificial skins and in disposable sensor labels.
Bernhard Lamprecht, Martin Sagmeister, Elke Kraker, Paul Hartmann, Georg Jakopic, Stefan Köstler, Harald Ditlbacher, Nicole Galler, Joachim Krenn, Birgit Ungerböck, Tobias Abel, Torsten Mayr
We present a novel waveguide sensor platform, combining monolithically integrated sensor waveguides with thin-film
organic photodiodes on a single substrate. Aiming at the parallel detection of multiple parameters in a single sensor chip
different sensing principles can be applied on the same basic sensor platform. Utilizing absorbance as sensing principle is
demonstrated by an integrated carbon dioxide sensor, fluorescence as sensing principle is demonstrated by an integrated
oxygen sensor. The versatility of this integrated waveguide platform is further demonstrated by employing surface
plasmon resonance as sensing principle, enabling real-time and label-free detection of a wide range of analytes.
Due to the light scattering processes that take place within the color conversion elements (CCE) of phosphor converted
light-emitting diodes (LEDs) and the rather different emission characteristics of the blue LED and the converted light,
which have to be matched by the scattering processes, a better understanding of the underlying physical aspects is
indispensable for device optimization. We give, based on optical ray-tracing, a comprehensive survey on the parameters
that effect color conversion and light scattering within the CCEs of phosphor converted LEDs. Studies range from
variations of the geometrical (height, width) to the compositional (concentration of the phosphor in the matrix material,
differences of the refractive indices of the matrix and the phosphor materials, phosphor particle size) parameters and
identify their respective impacts on the color temperatures and the luminous efficacies of the respective LEDs.
KEYWORDS: Light emitting diodes, Blue light emitting diodes, Quantum efficiency, Oxygen, Solid state lighting, Light sources, Near infrared, LED lighting, Radium, General lighting
White light of superior quality is characterized by high efficiency, high color rendering, and suitable spectral shape.
Color conversion from semiconductor light sources by use of phosphors appears to be a promising route to cover the
customer needs, and in the past a lot of different approaches have been pursued. There are not so many really successful
phosphor systems on the market, which is due to the industrial focus on blue LEDs as the excitation source, the
increasingly high demands on thermal and photochemical stability (high-power LEDs provide enormous irradiances),
and patent limitations. This paper reviews some concepts on color conversion including not only broadly used downconversion
but also novel up-conversion principles and discusses the pro's and con's of these approaches.
Today's most common approach for solid state lighting relies on the conversion of a portion of the blue light emitted
from the LED die by an inorganic phosphor material. Although this concept, at a first glance, seems to be rather simple,
the appropriate shape of the color conversion element (CCE) in white LED light sources turns out to have essential
significance for the quality of the white light (especially in terms of angular homogeneity). In this contribution we
discuss recent developments and novel coating concepts for LEDs that excel in terms of spatial homogeneity of the
emission and variability of the color temperature, which on the one hand can be attributed to the application of Silicate
based phosphors, a beneficial class of luminescent materials for LED application, and on the other hand on optimized
CCE geometries, which were obtained by numerical calculations with the help of state-of-the-art simulation tools.
Solid state lighting offers a lot of novel prospects for tomorrows customized lighting solutions. None the less, to compete
with and to surpass the performance of the traditional lighting systems, design and development of LED light sources is
still facing the necessity of further improvements, in particular with respect to device efficiency and light control. In this
contribution we discuss recent developments and novel strategies in order to improve the light extraction efficiency as
well as to affect the directionality of the light emitted from high power LEDs. In order to be up to characterize these
modifications with high spatial resolution, novel characterization techniques, like the implementation of a confocal
principle into the measurement set-up are discussed.
To compete with and to surpass the performance of traditional lighting systems, white LED development is still facing
the necessity of further improvements. An important topic that has to be addressed in this context is the spatial
homogeneity of the white light emitted, an issue that is directly associated with the geometry and the composition of the
color conversion elements (CCE) in phosphor converted LEDs. In order to avoid the need for experimental realization
and inspection of a large number of different configurations and compositions, optical simulation provides a time- and
cost saving alternative. In this contribution we discuss a simulation procedure which allows us to predict optimized
solutions for the CCEs in white LED light sources. The simulation process involves the set-up of a model for the blue
emitting LED chip and the implementation of a multitude of different geometries and compositions of individual CCEs
on top of the chip. Since the light is scattered within the CCEs, the respective scattering model, which considers the
phosphor particle size distribution and the phosphor weight fraction is of particular importance. In the final sequence of
the modeling procedure color uniformity is checked by monitoring the irradiance distributions both for the blue LED
light and the yellow converted light separately on a detector. From a comparison of the simulation results for a
significant number of different layouts we can deduce the impact of the individual materials parameters and predict
optimized CCEs which are finally compared with real device set-ups in order to verify the accuracy of the simulation
procedure.
Key market requirements for white LEDs, especially in the general lighting and automotive
headlamp segments call for improved concepts and performance of white LEDs based on phosphor
conversion.
Major challenges are small emission areas, highest possible intensities, long-term color stability, and
spatial homogeneity of color coordinates. On the other hand, the increasingly high radiation power of
the blue LEDs poses problems for all involved materials. Various thick film coating technologies are
widely used for applying the color conversion layer to the semiconductor chip. We present novel
concepts based on Silicate phosphors with high performance in terms of spatial homogeneity of the
emission and variability of the color temperature. Numerical calculation of the optical properties
with the help of state-of-the-art simulation tools was used as a basis for the practical optimization of
the layer geometries.
With the advent of a new generation of high brightness LEDs especially in the blue spectral range, white light
technology based on phosphor conversion gains maturity for a successful penetration of, e.g., the general lighting market
within the next years. Major challenges ahead are originating from the specific demands of the markets on small
emission areas, highest possible intensities, long-term color stability, and spatial homogeneity of color coordinates. The
LED industry more or less relies on the conversion phosphor classes of YAG, Sulfates, and Silicates, embedded in
silicone matrices. A number of conformal coating technologies are in use. The optimization of the coating geometries
with the help of software simulation offers a high potential for increased angular color homogeneity and high package
densities, especially when secondary optics is in use. We report on recent progress in simulating parameters for
improved white LEDs manufactured by coating technologies.
At present, light-emitting diode (LED) modules in various shapes are developed and designed for the general lighting, advertisement, emergency lighting, design and architectural markets. To compete with and to surpass the performance of traditional lighting systems, enhancement of Lumen output and the white light quality as well as the thermal management and the luminary integration are key factors for success. Regarding these issues, white LEDs based on the chip-on-board (COB) technology show pronounced advantages. State-of-the-art LEDs exploiting this technology are now ready to enter the general lighting segments. We introduce and discuss the specific properties of the Tridonic COB technology dedicated for general lighting. This technology, in combination with a comprehensive set of tools to improve and to enhance the Lumen output and the white light quality, including optical simulation, is the scaffolding for the application of white LEDs in emerging areas, for which an outlook will be given.
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