Ceramic Phosphor Plate with Layered Matrix for Lighting
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Solution Overview
Problem
Conventional phosphor-based lighting devices face issues such as reduced reliability due to high temperature and moisture sensitivity, material cost increases from using substrates, light losses, and structural defects in phosphor plates, which affect optical efficiency and durability.
Innovation Solution
A ceramic phosphor plate with a first short-wave phosphor layer and a second long-wave phosphor layer in a transparent ceramic matrix, reducing the use of high-priced long-wave phosphor and enabling adjustable color temperature, improved physical properties, and reduced defect rates through a phosphor-transparent ceramic composite composition with a binder cross-linked by heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate base substrate is used to coat the phosphor, then the phosphor can be supported and protected, but material costs increase and optical efficiency decreases due to partial transmittance losses
Solution Approach 1:
The patent merges the substrate function and phosphor coating into a single integrated phosphor plate structure. The transparent ceramic matrix itself serves as the supporting substrate while simultaneously housing the phosphor particles, eliminating the need for a separate base substrate and reducing optical interface losses.
Solution Approach 2:
The patent uses a composite structure consisting of transparent ceramic matrix material combined with phosphor particles dispersed within it. This composite approach provides both mechanical support from the ceramic matrix and phosphorescent functionality from the embedded phosphor particles, eliminating the need for separate substrate and coating layers.
2Adaptability or versatility
If two kinds of phosphors are mixed to set a specific color temperature, then color temperature can be adjusted, but absorption and emission wavelengths overlap causing reduction of properties
Solution Approach 1:
The patent applies local quality by creating distinct first and second phosphor layers with different phosphor compositions and characteristics. The first phosphor layer handles specific wavelength ranges while the second phosphor layer handles other wavelength ranges, allowing color temperature adjustment without harmful overlap between absorption and emission spectra.
3Ease of manufacture
If glass powder and phosphor are used to produce a phosphor plate, then a composite structure can be formed, but structural defects such as pores are generated reducing strength
Solution Approach 1:
The patent uses a composite material system combining transparent ceramic matrix with phosphor particles. This composite approach allows formation of a dense, defect-free structure where the ceramic matrix provides mechanical strength while accommodating the phosphor particles, eliminating pores and structural defects associated with traditional glass powder methods.
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 reduces production costs, enhances optical efficiency, and improves the color rendering index while minimizing physical damage during processing and operational environments, maintaining high transmittance and optical efficiency.
Implementation Method 1
a binder compound containing at least one silicate and cross-linked by heat treatment
Implementation Method 2
binder compound containing at least one silicate and cross-linked by heat treatment
Implementation Method 3
a first phosphor layer containing a short-wave phosphor and a second phosphor layer containing a long-wave phosphor
Data Source
Figure 1~2
Figure 3(a)~3(b)
Figure 4(a)~5
AI summary
Provided is a ceramic phosphor plate (100 ; 200 ; 1200 ; 2200) including a first phosphor layer (110 ; 210) containing a short-wave phosphor (1210) in a transparent ceramic matrix and a second phosphor layer (120 ; 220) containing a long-wave phosphor (1220), thereby enabling the reduction of a production cost by reducing an amount used of the high-priced long-wave phosphor (1220) (red phosphor).