Ceramic Conversion Element With Segmented Phosphor Layers
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Solution Overview
Problem
Existing ceramic conversion elements face challenges in manufacturing complexity and reabsorption of converted radiation due to the combination of different phosphors, particularly when using nitridic and oxide-containing phosphors, which degrades during high-temperature sintering.
Innovation Solution
A ceramic conversion element comprising two or more ceramic layers with distinct oxygen-containing inorganic phosphors, such as Ln3(Al5O12):Ce3+, arranged in direct contact and sintered together to form a monolithic, mechanically stable structure, allowing for simplified production and reduced reabsorption of converted radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different phosphors (nitridic and oxide-containing) are combined in a single ceramic conversion element, then the conversion efficiency and spectral range are improved, but the manufacturing complexity increases and reabsorption of converted radiation occurs
Solution Approach 1:
The conversion element is divided into multiple ceramic layers, with each layer containing a specific phosphor material optimized for particular wavelength conversions. This segmentation allows each layer to be independently manufactured and optimized, reducing overall manufacturing complexity while maintaining high conversion efficiency across different spectral ranges.
Solution Approach 2:
The patent transitions from a homogeneous mixed-phosphor approach to a stratified layered structure, adding the dimensional aspect of layering. This vertical arrangement of different phosphor layers enables independent optimization of each layer's composition and thickness, simplifying the manufacturing process while avoiding reabsorption issues that occur in mixed formulations.
2Adaptability or versatility
If multiple phosphors are combined in the same ceramic layer, then the spectral coverage is improved, but reabsorption of converted radiation degrades performance
Solution Approach 1:
Different phosphors are segregated into separate ceramic layers rather than being mixed in the same layer. This spatial segmentation ensures that converted radiation from one phosphor layer does not encounter and get reabsorbed by another phosphor, as each layer is positioned to convert specific wavelength ranges without interference from other phosphors.
Solution Approach 2:
Each ceramic layer is designed with specific local properties - particular phosphor compositions, thicknesses, and optical characteristics - optimized for its specific wavelength conversion function. This local optimization allows each layer to efficiently convert its designated wavelength range while minimizing reabsorption by other layers.
3Adaptability or versatility
If nitridic and oxide-containing phosphors are used together, then the conversion range is improved, but degradation occurs during high-temperature sintering
Solution Approach 1:
Nitridic and oxide-containing phosphors are separated into different ceramic layers, allowing each layer to be sintered under conditions optimized for its specific phosphor type. This eliminates the compatibility issues that arise when attempting to sinter mixed phosphor types together at high temperatures, as each layer undergoes thermal processing appropriate to its material composition.
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 efficient conversion of electromagnetic radiation across different wavelength ranges with reduced reabsorption, resulting in a broad spectrum of mixed-color radiation suitable for applications like flashlights or optoelectronic semiconductor components, improving handling and conversion efficiency.
Implementation Method 1
a first phosphor, which converts electromagnetic radiation of a first wavelength range into electromagnetic radiation of a second wavelength range
Implementation Method 2
the ceramic layers of the conversion element are bonded to one another in an integrally joined and mechanically stable manner
Data Source
AI summary
A ceramic conversion element includes a first ceramic layer having a first luminescent material, which transforms electromagnetic radiation of a first wavelength range into electromagnetic radiation of a second wavelength range. A second ceramic layer includes a second luminescent material, which transforms electromagnetic radiation of the first wavelength range into electromagnetic radiation of a third wavelength range. The first luminescent material and the second luminescent material are based on at least one inorganic compound containing oxygen and are different from one another. An optoelectronic component with a ceramic conversion element and a method for producing a ceramic conversion element are also specified.