Ceramic Composite Material for LED Light Emission
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Solution Overview
Problem
Ceramic composite materials used in light emitting devices with fluoride binders have poor thermal conductivity and low light emission intensity due to the presence of fluoride, which affects their performance in converting light from LEDs and LDs.
Innovation Solution
A method for producing a ceramic composite material involving a nitride fluorescent material and aluminum oxide particles, sintered at high temperatures to form a base material with high thermal conductivity, enhancing light emission intensity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluoride inorganic binder is used to produce ceramic composite material, then the material can be formed with fluorescent material, but the thermal conductivity becomes poor and light emission intensity is low
Solution Approach 1:
The patent removes the fluoride inorganic binder from the ceramic composite material composition entirely, replacing it with an organic binder. This extraction of the harmful fluoride component eliminates the root cause of poor thermal conductivity and low light emission intensity, allowing the fluorescent material to perform optimally without fluoride-related degradation.
Solution Approach 2:
The patent changes the chemical composition parameters by substituting fluoride-based binders with organic binder materials. This parameter change fundamentally alters the thermal and optical properties of the composite, enabling high thermal conductivity and high light emission intensity simultaneously by eliminating the fluoride constraint.
2Reliability
If fluoride is used as binder in ceramic composite material, then the material can be sintered and formed, but the light emission intensity becomes low
Solution Approach 1:
The patent extracts and removes the fluoride inorganic binder from the formulation, replacing it with an organic binder that enables effective sintering without compromising light emission intensity. This substitution maintains manufacturability while eliminating the harmful effects of fluoride on optical performance.
3Temperature
If ceramic composite material contains fluoride, then it can be produced with fluorescent material, but thermal conductivity remains poor
Solution Approach 1:
The patent completely removes fluoride from the ceramic composite material by replacing fluoride inorganic binders with organic binder materials. This extraction eliminates the substance causing poor thermal conductivity, enabling the material to achieve high thermal conductivity suitable for LED heat dissipation applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting ceramic composite material exhibits high light emission intensity and thermal conductivity, improving the performance of light emitting devices by effectively converting light from LEDs and LDs while maintaining mechanical strength and handleability.
Implementation Method 1
A light emitting device using a light emitting element, such as LED and LD, is a light source having a high conversion efficiency... a light emitting device having a combination of a light emitting element and a fluorescent material and emitting mixed light thereof
Implementation Method 2
preparing a green body containing a nitride fluorescent material having a composition represented by the following chemical formula (I) and aluminum oxide particles mixed with each other; and primary sintering the green body at a temperature in a range of 1,250° C. or more and 1,600° C. or less
Data Source
AI summary
Provided are a method for producing a ceramic composite material that has a high light emission intensity, a ceramic composite material, and a light emitting device. The method for producing a ceramic composite material, includes: preparing a green body containing a nitride fluorescent material having a composition represented by the following chemical formula (I) and aluminum oxide particles mixed with each other; and performing primary sintering the green body at a temperature in a range of 1,250° C. or more and 1,600° C. or less to provide a first sintered body:MwLn1xAyNz (I)wherein in the chemical formula (I), M represents at least one element selected from the group consisting of Ce and Pr; Ln1 represents at least one element selected from the group consisting of Sc, Y, La, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu; A represents at least one element selected from the group consisting of Si and B; and w, x, y, and z each satisfy 0<w≤1.0, 2.5≤x≤3.5, 5.5≤y≤6.5, and 10≤z≤12.