Ceramic Conversion Element Inhibitor Layer Ion Diffusion
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Solution Overview
Problem
Existing ceramic conversion elements are difficult to handle and produce, and semiconductor chips that emit white mixed-colored light in the warm-white range are not efficiently addressed by current technologies.
Innovation Solution
A ceramic conversion element with an active ceramic layer that converts electromagnetic radiation from one wavelength range to another, using a carrier layer and an inhibitor layer to manage radiation transmission and diffusion, allowing for efficient wavelength conversion and stable mechanical support, and a method of producing this element by applying and sintering ceramic layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the activator concentration in the active ceramic layer is increased to improve wavelength conversion efficiency, then the conversion efficiency improves, but the diffusion of activator ions into the carrier layer increases causing color variations
Solution Approach 1:
An inhibitor layer is introduced between the active ceramic layer and the carrier layer to prevent the diffusion of activator ions from the active layer into the carrier layer. This intermediary layer allows high activator concentrations to be used in the active layer for improved conversion efficiency while maintaining color homogeneity by blocking ion migration.
2Manufacturing precision
If a thin active ceramic layer is used to improve color homogeneity and reduce activator diffusion, then color variations are reduced, but the mechanical stability and handleability of the conversion element deteriorates
Solution Approach 1:
The conversion element is segmented into multiple functional layers: a thin active ceramic layer for wavelength conversion, an inhibitor layer for preventing ion diffusion, and a carrier layer for mechanical support. This segmentation allows the active layer to be thin for color homogeneity while the carrier layer provides the necessary mechanical stability.
Solution Approach 2:
The conversion element uses a composite structure combining different ceramic materials with distinct functions: the active ceramic layer contains activators for wavelength conversion, the inhibitor layer prevents ion diffusion, and the carrier layer provides mechanical strength. This composite approach resolves the contradiction between thin layer requirements and mechanical stability.
3Adaptability or versatility
If the activator concentration is increased to expand the color locus range, then the color rendering capability improves, but the diffusion of activator ions into the carrier layer increases causing undesirable color variations
Solution Approach 1:
The inhibitor layer acts as a barrier that enables the use of high activator concentrations to expand the color locus range while preventing the harmful diffusion of activator ions into the carrier layer, thus maintaining color homogeneity across the conversion element.
4Productivity
If the thickness of the active ceramic layer is increased to improve wavelength conversion efficiency, then the conversion efficiency improves, but the color homogeneity and activator concentration uniformity deteriorates
Solution Approach 1:
The conversion element is segmented into multiple functional layers: a thin active ceramic layer for wavelength conversion, an inhibitor layer for preventing ion diffusion, and a carrier layer for mechanical support. This segmentation allows the active layer to be thin for color homogeneity while the carrier layer provides the necessary mechanical stability.
Solution Approach 2:
An inhibitor layer is introduced between the active ceramic layer and the carrier layer to prevent the diffusion of activator ions from the active layer into the carrier layer. This intermediary layer allows high activator concentrations to be used in the active layer for improved conversion efficiency while maintaining color homogeneity by blocking ion migration.
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 solution enables the production of ceramic conversion elements that can emit white light with improved color homogeneity and efficiency, allowing for a wider color locus range and increased activator concentration, while maintaining mechanical stability and reducing undesirable variations in light color.
Implementation Method 1
an active ceramic layer that converts electromagnetic radiation in a first wavelength range into electromagnetic radiation in a second wavelength range
Implementation Method 2
an inhibitor layer reducing diffusion of activator ions from the active layer into the carrier layer
Data Source
AI summary
A ceramic conversion element includes an active ceramic layer that converts electromagnetic radiation in a first wavelength range into electromagnetic radiation in a second wavelength range, which is different from the first wavelength range, and a carrier layer transmissive to radiation in the first wavelength range and/or radiation in the second wavelength range, wherein an inhibitor layer is arranged between the active layer and the carrier layer, the inhibitor layer reducing diffusion of activator ions from the active layer into the carrier layer.