Ceramic Conversion Element with Intermediate Layers
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Solution Overview
Problem
The sintering process for ceramic conversion elements can cause damaging reactions and diffusion between luminous layers, altering their properties and reducing efficiency, especially when converting blue light into white light.
Innovation Solution
The method involves using at least four functional layers, with intermediate layers made of similar materials to the luminous layers, which are arranged to prevent direct contact and thus minimize reactions during sintering, and incorporating scattering centers to enhance light coupling-out efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sintering process is used to mechanically connect functional layers, then the layers are firmly bonded together, but damaging reactions and diffusion occur between luminous layers altering their properties
Solution Approach 1:
The patent introduces intermediate layers between the first luminous layer (oxide) and second luminous layer (nitride). These intermediate layers act as protective barriers that prevent direct contact between the luminous layers during sintering, thereby preventing damaging chemical reactions and diffusion while still allowing mechanical connection of all layers. The intermediate layers are positioned strategically to isolate the luminous layers from harmful interactions.
Solution Approach 2:
The patent segments the functional layers into distinct groups: first luminous layer, intermediate layers, and second luminous layer. This segmentation creates physical separation between the oxide-based and nitride-based luminous layers, preventing direct interaction during the sintering process while maintaining the overall structural integrity of the conversion element.
2Reliability
If intermediate layers are added to prevent reactions, then luminous properties are maintained, but device complexity increases
Solution Approach 1:
The intermediate layers serve as thin protective barriers that prevent chemical reactions between luminous layers. By using thin intermediate layers rather than thick buffer layers, the patent minimizes the increase in overall device complexity while still achieving the protective function. The intermediate layers are integrated into the existing layer structure without requiring additional complex processing steps.
3Reliability
If luminous layers are kept separate to prevent reactions, then material properties are preserved, but light coupling-out efficiency decreases
Solution Approach 1:
The patent applies local quality by making the intermediate layers transparent to the wavelengths of light generated by the luminous layers. This allows the intermediate layers to perform their protective function locally at the interfaces between luminous layers, while not interfering with the light transmission and coupling-out efficiency in the bulk regions. The luminous layers maintain their optical properties while being protected from chemical reactions.
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
This approach prevents damaging processes during sintering, maintains the luminous properties of the layers, and increases the efficiency of the ceramic conversion element by allowing partial conversion of blue light into white light with improved color rendering.
Implementation Method 1
The first luminous layer comprises an oxide and is configured for at least partially converting light of a first wavelength range into light of a second wavelength range
Implementation Method 2
The second luminous layer comprises a nitride and is also configured for at least partially converting light of the first wavelength range into light of a third wavelength range
Implementation Method 3
The functional layers are arranged such that... Then, the functional layers are mechanically connected together using at least one sintering process
Data Source
AI summary
A method for producing a ceramic conversion element and a light-emitting device are disclosed. In an embodiment the method includes providing at least four functional layers, each being a green body or a ceramic, wherein first functional layer is formed as a first luminous layer comprising an oxide and configured to at least partially convert light of a first wavelength range into light of a second wavelength range, wherein a second functional layer is formed as a second luminous layer comprising a nitride and configured to at least partially convert light of the first wavelength range into light of a third wavelength range, wherein a third functional layer is formed as a first intermediate layer, wherein the first intermediate layer comprises an oxide, wherein a fourth functional layer is formed as a second intermediate layer, and wherein the second intermediate layer comprises a nitride or an oxynitride.