Backlight Using High-Powered Corner LED
Various embodiments of corner-coupled backlights are described, where one or more LEDs are optically coupled to a truncated corner of a solid rectangular light guide backlight. In one embodiment, a high-power, white light LED is mounted in a small reflective cavity, which is then coupled to a flattened corner of the light guide. The reflective cavity provides a more uniform light distribution at a wide variety of angles to the face of the truncated corner to better distribute light throughout the entire light guide volume. This creates a more uniform light guide emission into the liquid crystal layers. In other embodiments, an LED is mounted in a small cavity near a corner of the light guide, and a reflector is mounted on the corner of the light guide. Various techniques for removing heat from the LED without adding additional area requirements are also disclosed.
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This invention relates to backlights for liquid crystal displays and, in particular, to illuminating the backlight using a light emitting diode (LED).
BACKGROUNDThere are many type of backlights used for liquid crystal displays (LCDs). Generally, for full color backlights, the light used to illuminate the backlight has red, green, and blue components. Fluorescent lamps are most commonly used as the light source. With the development of high power LEDs, such LEDs have been replacing the fluorescent lamps in some applications. A combination of red, green, and blue LEDs may be used, or “white light” LEDs may be used. A white light LED uses a blue or UV LED coated with a wavelength-converting phosphor so that the resulting light appears white.
A typical backlight for a small or medium size LCD uses a solid, transparent light guide formed of a polymer. The light source, either a fluorescent bulb or LEDs, is optically coupled to one side edge of the rectangular light guide. The light guide may be in the shape of a wedge or have facets or other types of reflectors that uniformly leak light out of the face of the light guide onto the liquid crystal layers. The red, green, and blue pixel locations of the liquid crystal layer are controlled by electrical signals to effectively act as light shutters for the RGB pixels to create a color image on the LCD screen.
In backlights where only one or a small number of LEDs are used, it is known to form the light guide to have a flattened corner edge, such as a 45 degree angle corner, and mount the LED package in contact with the face of the truncated corner. This is described in U.S. Pat. No. 7,001,058. A suitable LED package for mounting at the corner may be that described in U.S. Pat. No. 6,953,952, which shows an LED package with a window having an area less than 3 mm2. Both patents are incorporated herein by reference. By coupling the LED to the flattened corner, rather than to a relatively long side of the light guide, the light more fully spreads throughout the light guide volume to provide a more uniform illumination of the liquid crystal layers. However, with such corner-coupled LEDs, there is still significant optical coupling inefficiency and nonuniformity, and such backlights have only been suitable for small backlights due to the small coupling area. The nonuniformity is partially a result of a point source of light being applied to a surface of the light guide, rather than a wide homogeneous light source, such as a fluorescent bulb, applied to the surface of the light guide. Further, there are variations in the light emitted by the LED, such as due to color variations across the LED due to uneven deposition of phosphor, or variations in the emission profile of the LED die itself, or varying properties in the LED package. Additionally, if high power LEDs are used, it is difficult to remove heat from the LED without incurring additional area requirements.
SUMMARYVarious embodiments of corner-coupled backlights are described, where one or more LEDs are optically coupled at or proximate to a corner of a rectangular light guide backlight.
In one embodiment, a high-power, white light LED is mounted in a small reflective cavity, whose open end is then optically coupled to the face of a truncated (e.g., flattened) corner of the light guide. The reflective cavity provides a more uniform light distribution at a wide variety of angles to the face of the truncated corner to better distribute light throughout the entire light guide volume.
Because the LED is housed in the reflective cavity and thus separated from the light guide surface, there is a reduced angle between the light guide coupling surface and the LED. Thus, the maximum angle of light from the LED directly impinging on the light guide surface without being reflected by the reflective cavity is relatively small (e.g., 30-60 degrees relative to a line normal to the LED surface). The light emitted by the LED at wider angles is first reflected by the reflective cavity prior to being incident upon the surface of the light guide. The reflective cavity thus acts to spread out the LED light before impinging on the light guide surface so that the light fills the entire volume of the light guide. Further, variations in the light emitted by the LED itself are smoothed out by the reflective cavity and the separation of the LED from the light guide surface. This creates a more uniform light guide emission into the liquid crystal layers.
Various types of reflective cavities are described, along with various shapes of the truncated corner portion of the light guide.
One or more LEDs may be mounted in the same cavity. In one embodiment, to create white light, a wavelength-converting phosphor is located over a blue or UV LED. In another embodiment, red, green, and blue LEDs are located in the same reflective cavity. Other combinations of LED types are described.
LEDs may be coupled to any number of the four corners of the light guide for additional brightness or uniformity.
In other embodiments, a side-emitting LED is mounted in a small cavity (e.g., a hole) near a corner of the light guide, and a reflector is mounted on the corner of the light guide.
Other embodiments are also described.
Elements labeled with the same numerals in the various figures may be the same or equivalent.
DETAILED DESCRIPTIONThe LED die 26 is mounted on a submount 30. Metal pads on the LED die 26 are bonded to corresponding pads on the submount 30. The LED die 26 may be a flip-chip, or the bonds may be by wires. The submount 30 has terminals that electrically connect to a power supply. The submount 30 may be bonded to a printed circuit board (PCB) by direct bonding or wire bonding, where the PCB has an electrical connector for connection to the power supply. In addition to the submount 30 acting as an electrical interface between the power supply and the LED die, the submount 30 also acts as a heat sink to remove heat from the LED die 26. The top surface of submount 30 may be reflective to reflect the LED light towards the light guide 16.
Typical sizes for LED dies are 0.3 mm to 1 mm. The LED die 26 is preferably a high power LED so that only one LED is needed for the backlight. In one embodiment, the LED emits between 10-200 lumens and can handle drive currents ranging between 100 mA and 1.5 Amps. It is anticipated that the typical LEDs used in most embodiments will have a maximum power rating of at least 0.5 W. In the future, a single LED may replace a single fluorescent bulb typically used for backlights in laptop computers and other medium size LCDs. Currently, 2-4 LEDs are required to replace a single fluorescent lamp, depending on the size of the backlight.
The LED die 26 is encapsulated by a lens 32. The lens 32 may have a diameter of 2-6 mm. For very thin light guides, even the 2 mm lens is too big and may be deleted.
The inner walls of the reflective cavity 12 may be highly reflective enhanced aluminum or silver coated mirrors or other reflective material so that virtually all light entering the cavity 12 exits into the light guide 16. Suitable aluminum mirrors are available from Alanod Corporation and reach reflectivities of 92-97%. The cavity 12 may be clamped on or affixed onto the light guide 16 with an adhesive. The submount 30 may be snapped into place on the cavity 12 or affixed with an adhesive or by other means.
For optimum uniformity of light output by the light guide, the opening of the reflective cavity 12 should approximately match the face of the flattened portion of the corner (or other shape of the corner) so there are no light voids at the edges of the corner in the light guide. Also by providing a large opening of the cavity 12, the light becomes incident upon the light guide surface with fewer reflections by the cavity 12. For purposes of this disclosure, approximately matching the opening of the cavity to the face of the truncated corner is a matching within 75-100%, meaning that at least 75% of the corner face is covered by the cavity 12. The light output opening of the reflective cavity will typically be at least 4 mm2, corresponding to a relatively small corner coupling area.
By locating the LED die 26 further away from the light guide 16, the angle α becomes smaller. This angle α is in accordance with the equation tan α=w/2d, where w is the total width of the flattened corner and d is the distance from the LED die 26 to the middle of the flattened corner. A good tradeoff between uniformity, size of cavity, and in-coupling efficiency is to cause the angle α to be between about 30-60 degrees. This results in the distance d to be in the range of about w/3.5 to w/2; however, a distance d of w/5 (corresponds to α=68 degrees) or greater may be suitable. The larger the corner face, the larger the reflective cavity 12 will be. The LED die will typically be within a distance of 1-15 mm from the in-coupling surface of the light guide. A distance of 1 mm would correspond to a corner edge width of 3.5 mm for a 60 degree beam illumination, and 15 mm would correspond to a corner edge width of 17.5 mm for a 30 degree beam illumination.
Thus, the maximum angle α of light from the LED directly impinging on the light guide surface without first being reflected is smaller compared to the prior art, where the LED is essentially adjacent the corner face. The light emitted by the LED at angles wider than α is first reflected by the reflective cavity 12 prior to being incident upon the surface of the light guide 16. The reflective cavity 12 thus acts to spread out the LED light over the entire opening of the cavity 12, similar to the effect of a fluorescent bulb. This creates a more uniform distribution of light in the light guide volume, as opposed to a point source of light being coupled into the light guide.
Any number of corners (1-4) of the light guide 16 may be flattened and have LEDs housed in reflective cavities mounted thereon as shown in
The complexity of achieving good uniformity out of the light guide can be greatly reduced if good uniformity is achieved over the in-coupling edge. In
As shown in
For color point control, an optical feedback sensor 42 can be integrated into the reflective cavity 12, for example near the bottom of the side mirrors. The feedback sensor 42 may detect the relative intensities of the red, green, and blue color components and control currents to each of the LEDs to achieve a target color point. As an alternative to placing the optical feedback sensor 42 in the LED cavity, the sensor 42 can also be mounted on one of the edges of the light guide 16, opposite the light source.
In
As in all embodiments, additional LEDs may be used and additional corners may be coupled to the reflective cavities. Such would be the case for large LCD displays.
To reduce the total thickness of the LCD, the LED module can be placed in the same plane as the light guide plate, as shown in
As illustrated in
As in all embodiments, the LEDs can be various types using different phosphors and different direct LED colors to achieve the desired white point. For example, the phosphor may be YAG, or a combination of red and green phosphor, or a YAG and red phosphor. Instead of two blue LEDs being used, a blue and a red LED may be used, where a YAG or green phosphor plate near the cavity's exit is excited by the blue LED and allows the red light to pass through with little absorption. UV LEDs may also be used with suitable phosphors providing the red, green, and blue components.
It is preferable that the thermal resistance of the submount 30 material is 25K/W per LED or less.
In the embodiments of
In the embodiments of
In
In
In
Any combination of the embodiments is possible. All of the backlights may be used in the LCD embodiment of
Having described the invention in detail, those skilled in the art will appreciate that, given the present disclosure, modifications may be made to the invention without departing from the spirit of the inventive concept described herein. Therefore, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described.
Claims
1. A light emitting device comprising:
- a light emitting diode (LED) die;
- a reflective cavity housing the LED die, the cavity having an opening for light to exit, the opening having a cross-sectional area of at least 4 mm2; and
- a substantially rectangular light guide formed of a solid material having at least a first truncated corner, the truncated corner having a face, the light guide adapted for supplying light as a backlight;
- the opening of the reflective cavity opposing the face of the truncated corner such that light exiting the opening of the reflective cavity is coupled into the light guide through the face of the corner,
- where the LED die is at least 1 mm from the face of the truncated corner.
2. The device of claim 1 wherein an angle of a surface of the LED die to a far edge of the cavity opposing the face of the truncated corner is approximately 30-60 degrees.
3. The device of claim 1 wherein the opening of the cavity covers at least 75% of the face of the truncated corner.
4. The device of claim 1 wherein the opening of the cavity covers at least 90% of the face of the truncated corner.
5. The device of claim 1 wherein the LED die is at a distance d from the face of the truncated corner, and the truncated corner has a width of w, the LED die being a distance of at least d=w/5 from the face of the truncated corner.
6. The device of claim 1 wherein the LED die is at a distance d from the face of the truncated corner, and the truncated corner has a width of w, the LED die being a distance of at least d=w/3.5 from the face of the truncated corner.
7. The device of claim 1 wherein the LED die is at a distance d from the face of the truncated corner, and the truncated corner has a width of w, the LED die being a distance between w/2 and w/3.5 from the face of the truncated corner.
8. The device of claim 1 wherein the reflective cavity comprises a rectangular cavity.
9. The device of claim 1 wherein the reflective cavity comprises a rounded cavity.
10. The device of claim 1 wherein the reflective cavity comprises an elliptical cavity.
11. The device of claim 1 wherein the reflective cavity comprises a parabolic cavity.
12. The device of claim 1 wherein the LED die has a major surface facing the face of the truncated corner.
13. The device of claim 1 wherein the LED die has a side surface facing the face of the truncated corner.
14. The device of claim 1 wherein the LED is encapsulated by a lens.
15. The device of claim 1 wherein the face of the truncated corner is rounded.
16. The device of claim 1 wherein the face of the truncated corner is scalloped.
17. The device of claim 1 wherein the reflective cavity has reflective walls, wherein at least one wall extends over a surface of the light guide.
18. The device of claim 1 wherein the reflective cavity has reflective walls that taper towards the face of the truncated corner.
19. The device of claim 1 wherein the reflective cavity has walls that are specular.
20. The device of claim 1 wherein the reflective cavity has walls that are diffusing.
21. The device of claim 1 wherein the reflective cavity is substantially filled with an encapsulant.
22. The device of claim 1 wherein the reflective cavity has walls that provide a heat sink for the LED die.
23. The device of claim 22 wherein at least one wall of the reflective cavity extends over a portion of the light guide for conducting heat away from the LED die.
24. The device of claim 23 wherein the at least one wall of the reflective cavity that extends over a portion of the light guide acts as a reflector for reflecting light in the light guide towards an opposing surface of the light guide.
25. The device of claim 1 further comprising a heat conductive submount on which the LED die is mounted, the submount being thermally coupled to a back surface of the light guide.
26. The device of claim 1 further comprising a heat conductive submount on which the LED die is mounted, the submount being thermally coupled to a reflector on a back surface of the light guide.
27. The device of claim 1 further comprising liquid crystal layers overlying the light guide.
28. The device of claim 1 further comprising a phosphor in the reflective cavity for color conversion of light emitted by the LED die.
29. The device of claim 28 wherein the phosphor comprises at least one layer over the LED die for generating a white light into the light guide.
30. The device of claim 28 wherein the phosphor comprises a phosphor plate located closer to the face of the truncated corner than to the LED die for generating a white light into the light guide.
31. The device of claim 1 further comprising a diffuser between the LED die and the face of the truncated corner.
32. The device of claim 1 further comprising a plurality of LED dies in the reflective cavity.
33. The device of claim 32 wherein the LED dies comprise at least a blue LED die and an LED die that emits a different color.
34. The device of claim 32 further comprising an optical feedback sensor in the reflective cavity for detecting a color of light generated in the reflective cavity.
35. A light emitting device comprising:
- a light emitting diode (LED) die;
- a substantially rectangular light guide formed of a solid material having at least a first corner; and
- the light guide having a cavity proximate to the first corner, the light guide adapted for supplying light as a backlight,
- the LED die being mounted so as to emit light into the cavity formed in the light guide.
36. The device of claim 35 further comprising a side-emitting lens over the LED die such that light emitted from the lens is substantially directed toward a wall of the cavity.
37. The device of claim 35 further comprising a reflector around the first corner for reflecting light back into the light guide.
38. The device of claim 35 wherein the first corner is cusp shaped to redirect light.
39. The device of claim 35 further comprising a reflector over an end of the cavity to reflect light back into the cavity.
40. The device of claim 39 wherein the reflector is cone shaped.
41. The device of claim 39 wherein the reflector is cusp shaped.
42. The device of claim 39 wherein the reflector is patterned.
43. The device of claim 35 wherein the LED die is mounted within 15 mm from the first corner.
44. The device of claim 35 further comprising a phosphor in the cavity for color conversion of light emitted by the LED die.
45. The device of claim 35 further comprising additional LED dies in the light guide proximate to the first corner.
46. The device of claim 35 further comprising a heat conductive submount on which the LED die is mounted, the submount being thermally coupled to a back surface of the light guide.
47. The device of claim 35 further comprising a heat conductive submount on which the LED die is mounted, the submount being thermally coupled to a reflector on a back surface of the light guide.
48. The device of claim 35 further comprising liquid crystal layers overlying the light guide.
Type: Application
Filed: Aug 25, 2006
Publication Date: Feb 28, 2008
Applicant: PHILIPS LUMILEDS LIGHTING COMPANY, LLC (San Jose, CA)
Inventors: Gerard Harbers (Sunnyvale, CA), Mark Pugh (Los Gatos, CA), Serge Bierhuizen (Milpitas, CA)
Application Number: 11/467,499
International Classification: F21V 7/04 (20060101);