Look...
It's tricky ....
Not difficult to be made, just tricky ....
And has a lot of calculations (I do not like maths ! ) ...
...
Well ..
In the "phosphor & leds school " ( !!! ) of led growing ,there are some drawbacks ....
Main principle of that " school " is the use of various uv , violet & blue dies (led chips ) to excitate a phosphor layer ...
Say ordinary high power Phosphor white leds ....(not the RGB multichip ones )
-One drawback is the power losses that occur from phosphor layer and the "encapsulating " materials (soft silicones,usually ..) ,from absorption .
-Another drawback is the light that is emitted by the "phosphor" ,part of it returns to the led die ...
Die works both ways ..Making light from electricity ..Or making electricity from light ...
When doing both at same time ,efficiency(..of both actions ... ) drops ..
-Heat ...Longer Wavelength light from phosphor (more photons with less energy ,from the ones used for excitation ) ,going back to die ,rises Tj ...
-Heat ..from Die ..Destroys phosphor layer ,slowly....And efficiency drops during operation ..
And color shifts happen ...(towards blue ) through usage time (service life ).... Many bad things .....
Now...
Remote phosphors ....
The phosphor layer is far away (Ok ..Not that far away...Not kilometers or miles ...Few mm or cm ,only ) ,from the led die ....
-Heat does not alter the phosphor characteristics so drastically ...Prolonged life and stability of phosphor ....
-Light from phosphor that hits the chip ,turning it into a photovoltaic device is diminished greatly...
Most light from the "die side " of phosphor layer is reflected back( by ' mixing chamber ') to the illuminating side .....
Die efficiency increases ...
-Less heat generated at die ...Again ...Die efficiency increases ...
-The light ,that comes through the remote phosphor glass or polymer ,thin screen (1-2 mm thickness ) ,
is glare-free (no visible led sources underneath ) and of great -almost absolute -homogeneity ...(fully diffused )
....Like sunlight ,after passing through atmosphere,before falling on leaves (..Well...Kinda ...)
Tricky part A is mixing some phosphors ....
http://www.intematix.com/products/phosphors/led-phosphors
Consider phosphors as Green ,yellow ,orange and red leds ....
With remote phosphor method ,one can have
an array of 7x7 one watt chips (350mA )
One chip at 390-410
One at 430-440
One at 440-445
..445-450
..450-455
..455-460
&
..460-470 ..
Seven different dies of violet & blue light ...
Arranged in 7 rows or lines ...
( 50 Watt approx )
Place a heatsink on the array's back ...
Place a reflector (and diffusor at same time )
Place a phosphor doped plastic screen on top ...
Flip the switch ...
..
Now..." phosphor doped "....
Plenty of ways to do it ...
I.e .
Mix phosphor blend ( fine powders mixed together ) with " liquid glass " part A or
a fine grade extra transparent epoxy part A (or B ..) ....
Mix really well ...For long time ...
Place it maybe in Ultrasonic cleaner ....
Very good mixing is needed ...
Spray it over on a Plexiglass screen ....Or glass screen ...Or polycarbonate screen ...
(thin or thick layer of spray , depending on phosphor particle sizes ...And % of volume ,from each different phosphor in the "blend " / " mix " ...And of course depending on how much blue/violet is wanted to pass trough screen .....)
Clean the paint gun with acetone or something similar...
Now spray the screen again with part B (of "liquid glass " / liquid transparent epoxy ....(thinnest ,possible )
Let the bonding / curing to happen ...
Here you are ..
Your own remote phosphor screen ...
(Really simplified .... And just one of few different ways to make ... ) ..
Now the screen is your green ,yellow,amber,red and far red ....." leds " ...
Many maths here ..
Particle size of phosphor ,density ,volume(dimensions ) of screen ,
screen (substrate ) ang bonding (i.e. epoxy )material optical and chemical specs ,ect,ect....
But doable enough ,nevertheless....
What you get from this method firstly is "full " light ..From 390 up to 750 ...
Some light from dies (390-470 nm ) passes through screen (Another tricky part ...To adjust ..)
Most of light is at the range ,that the phosphor blend is made to emit...
Phosphor last for way longer and does not color shift ...
Led die Efficiency increases ...
Light is glare free and fully diffused...Almost absolute homogeneity...
....
And some more good ones....
I think that I like mostly that way ....
I'm bettin' on it ....
Say the remote phosphor " ASL 24 MK RP "panel ,has
4 x violet 390-410 nm ....
4 leds per panel aren't many at this case ..A lot of UV /viloet is blocked (absorbed or reflected back ),from PMMA -Polycarbonate-glass screen .... )
6 x 440-445 nm
4 x 445-450 nm
6 x 455-460 nm
4 x 465-475 nm
Starting from 390 nm up to 475 nm approx with a "pump-bump" at 440-460 nm ...
Overall % of power that passes through screen as light 390-475 nm is about 10-15% of total
flux....Maybe even ,a bit less (8-9% ) ....
The remaining 85-90 % of light power comes from remote phosphor excitation ...
( flouorescence ).....
Say we used one
green ( i.e peak at 510 nm ),one
yellow (580 nm ),one
orange (600 nm )and four
red (620-640-660-670 )phosphors at a certain analogy in between them ( volume-wise ) ...
Then applied the blend on a polycarbonate (transparent),say 0.8 mm thick, screen ...
Constructed (that is ,in fact,the most difficult part ) an efficient "mixing chamber "....
Highly reflective (>96% ) but also highly diffusive (>95% ) materials needed...
Can not just be mirror polished ally ....
It can be "hammered " pattern ally reflective sheet, though ...
Not the best material out there,but easy enough to obtain...
(....The absolute Best, would have been a plastic housing ,plated with those weird materials I/matix suggests ... )
...
.....Thinking of removing the plastic lenses of led units ..
Anyway mixing chamber enviroment is going to be totally isolated...
No need for protective lenses at leds ...
Can be just fine with their bare silicone domes exposed....
...
Testing is needed...
Maybe difference in efficiency is not going to be great ....
Or,maybe is...
...
Anyway...
A whole
Brave New ...way for growing ,this one , regarding leds ....
I trust is going to kick ......ok...
...ya'all know what ...