Nichia Corporation v Arrow Electronics Australia Pty Ltd
[2017] FCA 864
At a glance
Source factsCourt
Federal Court of Australia
Decision date
2017-08-02
Before
Yates J
Source
Original judgment source is linked above.
Judgment (57 paragraphs)
Introduction 1 The applicant, Nichia Corporation, is the patentee of Patent No. 720234 (the patent). It sues the respondent, Arrow Electronics Australia Pty Ltd, for infringement of claim 3 of the patent. Claim 3 is dependent on claim 1. 2 Claim 1 is: A light emitting device, including a light emitting component and a phosphor capable of absorbing a part of light emitted by the light emitting component and emitting light of wavelength different from that of the absorbed light; wherein said light emitting component comprises a nitride compound semiconductor and said phosphor contains a garnet fluorescent material including at least one element selected from the group consisting of Y, Lu, Sc, La, Gd and Sm, and at least one element selected from the group consisting of Al, Ga and In, and being activated with cerium. 3 Claim 3 is: A light emitting device according to claim 1, wherein the phosphor contains fluorescent material represented by a general formula (Rel-rSmr)3(Al1-sGas)5O12:Ce, where 0≤r60 is usually acceptable; >70 is usually acceptable for street lighting, and >80 is usually acceptable for house lighting. A CRI of ≥90 is used for specialty applications, such as museum display lighting and medical equipment.
The Specification 36 The specification discloses that various attempts have been made to make white light sources using light emitting diodes. It is common to refer to light emitting diodes as LEDs. I will do so in these reasons, although I note that the specification uses "LED" as the acronym for a "light emitting device". The specification uses the expression "light emitting device" to refer to a phosphor in combination with a "light emitting component" where the phosphor of the device converts the wavelength of the light emitted by the light emitting component. In other parts, the specification appears to use the expression "light emitting device" synonymously with a "light emitting diode". I do not think that anything turns on this. The specification identifies the "light emitting component" of the device as a nitride compound semiconductor. 37 The specification refers to the advantages of LEDs as a light source: they are compact and emit light of a clear colour with high efficiency; they are free from "burn-out" and have good initial drive characteristics; they have high vibration resistance, and high durability to endure repetitive on/off operations. The specification explains, however, that, although LEDs are effective as light emitting devices for generating monochromatic light (such as red, green and blue), a satisfactory light source capable of emitting white light using these components has not been obtained. 38 The specification discloses that the applicant had previously developed LEDs which use a fluorescent material to convert the colour of light that is emitted by the light emitting component. The specification identifies a number of patents held by the applicant which, the specification says, disclose LEDs that are capable of generating white light and other colours. The specification describes these LEDs as follows: The light emitting diode … are made by mounting a light emitting component, having a large energy band gap of light emitting layer, in a cup provided at the tip of a lead frame, and having a fluorescent material that absorbs light emitted by the light emitting component and emits light of a wavelength different from that of the absorbed light (wavelength conversion), contained in a resin mold which covers the light emitting component. The light emitting diode disclosed as describe above capable of emitting white light by mixing the light of a plurality of sources can be made by using a light emitting component capable of emitting blue light and molding the light emitting component with a resin including a fluorescent material that absorbs the light emitted by the blue light emitting diode and emits yellowish light. (As in original.) 39 The specification says that these "conventional" LEDs have problems. These problems centre on the deterioration of the fluorescent material. The deterioration arises from various causes. 40 First, there is deterioration of the fluorescent material arising from the amount of light energy the material absorbs from the light emitting component. The specification discloses that this is a problem with organic phosphors and some inorganic phosphors ((Cd,Zn)S is exemplified). The deterioration of the fluorescent material leads to colour tone deviation of the emitted light. It also leads to darkening of the material, which results in lowered efficiency in terms of "extracting light". 41 Secondly, there is deterioration brought about by the high temperature of the LED and heat transmitted from the external environment, such as sunlight when the device is used outdoors. 42 Thirdly, some fluorescent materials are subject to accelerated deterioration due to a combination of moisture (whether introduced from the outside or during the production process) and the light and heat transmitted from the light emitting component. 43 The specification also teaches that, where the fluorescent material is an organic dye, electrophoresis may result in a change in the colour tone of the emitted light. 44 The specification says that the invention aims to provide an alternative to known light emitting devices and displays, which alleviates at least one of the described problems to provide a light emitting device which experiences only extremely low degrees of deterioration in emission light intensity, light emission efficiency and colour shift over a long time of use, with high luminance. 45 The specification describes one aspect of the invention as a light emitting device that includes a nitride compound semiconductor component in combination with a phosphor that contains a garnet fluorescent material. The garnet fluorescent material must include certain identified elements. It is activated with Ce. 46 I pause to note that it is accepted that the nitride compound semiconductor emits blue light. The phosphor - the described garnet fluorescent material - is excited by the blue light emitted from the light emitting component, and emits yellow light. There is no dispute that blue light has a wavelength of approximately 450 nanometres (nm) and that yellow light has a wavelength in the range of approximately 500 to 700 nm. Thus, in the invention, the wavelength of the light emitted from the phosphor is longer than the wavelength of the light emitted from the light emitting component that is absorbed by the phosphor. The conversion of light from one wavelength to another is called spectral conversion. 47 The specification teaches that, generally, a fluorescent material which absorbs light of a short wavelength and emits light of a long wavelength (the specification is here discussing relativities) has higher efficiency than a fluorescent material which absorbs light of a long wavelength and emits light of a short wavelength. 48 The specification also teaches that it is preferable to use a light emitting component that emits visible light rather than ultraviolet (UV) light, because UV degrades the resin which is used as a moulding or coating material in the housing of the LED, which also includes the phosphor of interest embedded in the resin that coats the light emitting component. To this end, the specification teaches that it is preferable that the main emission peak of the light emitting component be set within a relatively short wavelength range of 400 nm to 530 nm, in the visible light region. 49 The blue light and the yellow light emitted by the light emitting component and the phosphor respectively, blend to produce white light. In its evidence and submissions, the applicant referred to a blue LED combined with fluorescent material to produce a white light source as a white LED. I will use the same expression. 50 For this embodiment, the specification expresses a preference for a phosphor that is an yttrium-aluminium-garnet fluorescent material (YAG phosphor) activated with Ce. The fluorescent material having the general formula in claim 3 is specifically referred to amongst other formulae: see [3] above. Although the specification uses a number of formulae, I will refer to the formula in claim 3 as the general formula. 51 The specification teaches that the wavelength of the light emitted from the YAG phosphor can be shifted to a shorter wavelength by substituting part of the Al in the phosphor with Ga. In this connection, the general formula comprehends the possibility of having only Al (and no Ga), or only Ga (and no Al), or a combination of both, in the phosphor. 52 Further, the general formula requires that the phosphor also include Y or Gd, or both. Sm can be present with the Y and/or Gd, but not alone. The specification teaches that the wavelength of the light emitted from the YAG phosphor can be shifted to a longer wavelength by substituting part of the Y in the phosphor with Gd. 53 Thus, the light colour emission can be changed continuously by changing the composition in the ways described immediately above. The specification also teaches that the addition of Sm will improve the efficiency of the light emission. 54 A second aspect of the invention is described in which a nitride compound semiconductor (represented by a given formula) is used in combination with a phosphor that contains one, two or more garnet fluorescent materials according to the general formula subject to the additional requirement that r≠0. 55 A third aspect of the invention is described in which a nitride compound semiconductor (represented by a given formula) is used in combination with a first fluorescent material (represented by a given formula) and a second fluorescent material (represented by another given formula). 56 A fourth aspect of the invention is described. It is a method of preparing a white light emitting device. 57 The following matters should be noted. 58 First, so far as fluorescent materials are concerned, the invention described in the specification is directed to the use of garnet fluorescent materials of a particular kind. Attention is directed to Y3Al5O12:Ce (YAG:Ce), or forms of that phosphor with substituents or additions, as the specified phosphor. Twelve examples of the use of such a phosphor are provided. In some examples, two such fluorescent materials are used. There are two comparative examples. The comparative examples do not use a garnet fluorescent material. 59 Comparative Example 1 concerns the use of cadmium zinc sulphide (Cd,Zn)S as the fluorescent material. As I have noted, the specification teaches that, in use, this material darkens and leads to lowered light-extracting efficiency. Nevertheless, the LED formed with this material showed, immediately after energisation, the emission of white light, albeit with low luminescence. Thus, it provided a white LED but not one that was satisfactory according to the teaching of the specification. I will refer again to this example when discussing the applicant's work directed to developing a white LED. 60 Comparative Example 2 concerns the use of two organic dyes rather than garnet fluorescent materials. As I have noted, the specification teaches that when organic dyes are used, electrophoresis may occur, resulting in a change in the colour tone of the emitted light. It is implicit in the description of Comparative Example 2 that white light was emitted. A weatherability test (equivalent to irradiating the material with sunlight for one year) and a reliability test (energising the material to emit light at a constant temperature of 70° C while measuring luminance and colour tone at different times) were carried out. When the LED of Comparative Example 2 was compared with the LED of Example 9, which used a combination of garnet fluorescent materials, the LED of Example 9 experienced less deterioration. Once again it would seem that the specification does not accept that Comparative Example 2 provides a satisfactory white LED. 61 Secondly, although the general formula of claim 3 covers a phosphor containing Sm as well as Y and/or Gd, and Ga as well as, or in substitution for, Al, it includes the phosphor YAG:Ce. Therefore, it can be said that, at its simplest, the light emitting device claimed in claim 3 is one in which a nitride compound semiconductor (the light emitting component) is combined with YAG:Ce. 62 Thirdly, claim 3 does not, in terms, require the creation of white light, nor white light of any particular nature, quality or colour rendering. Nor does it require that the light emitting device be suitable for any particular application; there are no requirements of stability, durability, efficiency or performance expressed as essential features of the invention. 63 Nevertheless, the specification makes clear that the invention is a light emitting device that emits white light. The present case is an example of where the context provided by the specification rises up to insist that claims 1 and 3 are directed to such a device: International Business Machines Corporation v Smith, Commissioner of Patents (1992) AIPC 90-853 at 38,160-38,161. The specification teaches that the wavelength of the emitted light (and hence its colour rendering) can be varied by choices made within the scope of the general formula. 64 Further, the specification makes clear that an object of the invention is to provide a light emitting device with high luminescence, and which experiences only extremely low degrees of deterioration in emission light intensity, light emission efficiency and colour shift over a long period of use. 65 In this connection, the specification states: The present applicant completed the present invention through researches based on the assumption that a light emitting device having a light emitting component and a fluorescent material preferably meets the following requirements to achieve the above-mentioned object. (1) The light emitting component is preferably capable of emitting light of high luminance with light emitting characteristic which is stable over a long time of use. (2) The fluorescent material being provided in the vicinity of the high-luminance light emitting component, preferably shows excellent resistance against light and heat so that the properties thereof do not change even when used over an extended period of time while being exposed to light of high intensity emitted by the light emitting component (particularly the fluorescent material provided in the vicinity of the light emitting component is exposed to light of a radiation intensity as high as about 30 to 40 times that of sunlight according to our estimate, and is required to have more durability against light as light emitting component of higher luminance is used). (3) With regard to the relationship with the light emitting component, the fluorescent material is preferably capable of absorbing with high efficiency the light of high monochromaticity emitted by the light emitting component and emitting light of a wavelength different from that of the light emitted by the light emitting component. (As in original.) 66 It can be taken that each embodiment of the invention that is claimed is a light emitting device (whether as an LED, a display device or some other light emitting device), or a method of preparing a light emitting device, that is directed to meeting these requirements. This is not to say that these requirements are imported as essential features of the invention that is claimed - as if the claims were limited by result. It does acknowledge, however, that the invention is directed to a white light emitting device that should attain these preferable (in the sense of desirable) attributes. These are the "promises" that the specification makes.