Chlorosilicate Fluorescent Material Surface Modification

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Solution Overview

Problem

Chlorosilicate fluorescent materials used in light emitting devices tend to deteriorate in high temperature and high humidity environments, leading to reduced durability.

Innovation Solution

A method of producing a fluorescent material with a chlorosilicate composition by calcining a mixture of Ca, Sr, Ba, Mg, Zn, Eu, Ce, Tb, Mn, Si, and Cl, and then treating it with a fluorine-containing substance in an inert gas atmosphere at temperatures between 200°C and 450°C to form a surface layer containing a fluorine-containing compound, enhancing durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a chlorosilicate fluorescent material is used to achieve high luminous efficiency, then the light emission performance is improved, but the durability deteriorates in high temperature and high humidity environments

Engineering Contradiction:
Improveluminous efficiencyVSAvoiddurability
Core Design Contradiction:
Use of energy by moving objectVSReliability

Solution Approach 1:

The patent applies composite materials by combining chlorosilicate fluorescent material with fluorine-containing compounds to form a surface-modified composite structure. The fluorine-containing compound forms a protective layer on the surface of the chlorosilicate particles, creating a composite material that retains the high luminous efficiency of the chlorosilicate while adding environmental stability and durability through the fluorine coating.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent uses an inert gas atmosphere (nitrogen or rare gas) during the heat treatment process to prevent unwanted chemical reactions and oxidation of the chlorosilicate fluorescent material. This inert environment protects the material during processing and contributes to the final product's resistance to environmental degradation in high temperature and humidity conditions.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

2Manufacturing precision

If the fluorescent material is heat-treated at high temperature to improve crystallinity, then the light emission characteristics are improved, but the material structure becomes unstable in humid environments

Engineering Contradiction:
ImprovecrystallinityVSAvoidstructural stability
Core Design Contradiction:
Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent performs heat treatment in an inert gas atmosphere (nitrogen or rare gas) to achieve high crystallinity without exposing the material to oxidizing or humid conditions during processing. This inert environment prevents structural degradation while allowing the beneficial crystalline structure to form, and the resulting structure maintains stability in subsequent humid service conditions.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The patent creates a composite structure where fluorine-containing compounds are incorporated into or on the crystalline chlorosilicate structure. This composite approach allows the material to achieve high crystallinity for improved light emission while the fluorine component provides environmental stability and protects the crystal structure from humidity-induced degradation.

Inventive Principle:
Principle #40Composite materials

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 resulting fluorescent material exhibits improved durability and resistance to environmental changes, maintaining light emission characteristics and stability under high temperature and humidity conditions.

Implementation Method 1

bringing the calcined product in contact with a fluorine-containing substance and heat-treating the calcined product in an inert gas atmosphere at a temperature in a range of 200° C. or more and 450° C. or less

Methodology Applied
Scientific EffectChemical Vapor Deposition: Chemical Vapour Deposition

Implementation Method 2

heat-treating the calcined product in an inert gas atmosphere at a temperature in a range of 200° C. or more and 450° C. or less

Methodology Applied
Scientific EffectHeat Treatment: Heat Treatment

Implementation Method 3

a light source with a wavelength conversion member capable of emitting light having a different hue from the hue of the light source through excitation with the light from the light source

Methodology Applied
Scientific EffectFluorescence: Fluorescence

Data Source

PatentUS10414976B2Method for producing fluorescent material, fluorescent material, and light emitting device using the same
Publication Date: 2019.09.17 NICHIA CORP
  • US10414976B2 patent drawing
  • US10414976B2 patent drawing
  • US10414976B2 patent drawing

AI summary

A method of producing a fluorescent material that is capable of providing a light emitting device having excellent durability, a fluorescent material, and a light emitting device are provided. The method of producing the fluorescent material includes: preparing a calcined product having a chlorosilicate composition containing at least one element selected from the group consisting of Ca, Sr, and Ba, at least one element selected from the group consisting of Mg and Zn, at least one element selected from the group consisting of Eu, Ce, Tb, and Mn, Si, O, and Cl; and bringing the calcined product in contact with a fluorine-containing substance and heat-treating the calcined product in an inert gas atmosphere at a temperature in a range of 200° C. or more and 450° C. or less.