Ceramic Converter Element with Embedded Phosphor for High Quantum Efficiency
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Solution Overview
Problem
Current methods for producing ceramic phosphor converters like YAG:Ce result in non-stoichiometric particles and undesirable phases, leading to low quantum efficiency and luminous flux.
Innovation Solution
A method using pre-synthesized phosphor powder embedded in a ceramic matrix, with controlled particle size and composition to maintain high quantum efficiency, involving mixing, milling, and sintering in specific atmospheres.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the mixed oxide approach is used to synthesize ceramic phosphor converter, then the synthesis process can be completed with standard oxide materials, but the reactions between oxides are not complete resulting in non-stoichiometric phosphor particles and undesirable phases leading to lower quantum efficiency
Solution Approach 1:
The patent applies preliminary action by pre-synthesizing stoichiometric phosphor particles before embedding them in the ceramic matrix. This ensures that the phosphor particles are already in the desired stoichiometric state with high quantum efficiency before the ceramic processing steps, preventing the formation of non-stoichiometric phases during sintering.
Solution Approach 2:
The patent uses a composite material approach by combining pre-synthesized phosphor particles with ceramic matrix materials. This allows the phosphor to maintain its optimal stoichiometry and quantum efficiency while being embedded in the ceramic structure, avoiding the formation of undesirable phases that occur when mixing oxides directly.
2Manufacturing precision
If the co-precipitated phosphor precursor synthesis approach is used, then fine phosphor particle size can be achieved, but unreacted phases like YAM and YAP are observed leading to color shift and low quantum efficiency
Solution Approach 1:
The patent applies preliminary action by pre-synthesizing phosphor particles with controlled fine particle size and correct stoichiometry before embedding them in the ceramic matrix. This preliminary synthesis ensures complete reaction and elimination of unreacted phases while maintaining the desired fine particle size for optimal optical properties.
Solution Approach 2:
The patent uses parameter changes by controlling the synthesis conditions of the phosphor particles to achieve the optimal particle size range and stoichiometry. By adjusting synthesis parameters such as precipitation conditions, temperature, and composition ratios, the patent achieves fine particle size without forming unreacted phases like YAM and YAP.
3Reliability
If pre-synthesized phosphor powder is embedded in ceramic matrix, then high quantum efficiency can be maintained, but additional processing steps are required
Solution Approach 1:
The patent merges the phosphor synthesis and ceramic matrix formation into a single integrated process. By embedding pre-synthesized phosphor particles in the ceramic matrix during the ceramic processing steps, the patent combines multiple functions (phosphor incorporation, matrix formation, and sintering) into one unified manufacturing process, reducing overall complexity despite the additional embedding step.
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
Achieves ceramic converter elements with quantum efficiency 2-3% higher than conventional processes, maintaining high conversion efficiency in optoelectronic devices.
Implementation Method 1
comprises phosphors which convert the primary radiation at least partially into a secondary radiation of a different wavelength
Implementation Method 2
processing the mixture to form a ceramic converter material
Data Source
AI summary
A method for producing a ceramic converter element is provided. The method includes providing a phosphor as a starting material, mixing the phosphor and at least one metal oxide powder to form a mixture, and processing the mixture to form a ceramic converter material in which the phosphor is embedded in a ceramic matrix. Further, an optoelectronic component with a ceramic converter element and a ceramic converter element are provided.