Conversion Element Production via Acidic Silicate Precipitation
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Solution Overview
Problem
Existing conversion elements in optoelectronic components, particularly inorganic light-emitting diodes, suffer from low aging stability and lack cost-effective production methods, which affects their high temperature and light resistance.
Innovation Solution
A method involving an acidic medium with a pH of less than 2, where a conversion material is added and mixed with a silicate solution of 2 to 10,000 poise viscosity, resulting in a precipitate of conversion material and silicon dioxide, which is then washed and cured to produce a stable conversion element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conversion elements are made of silicon or ceramic matrix material with embedded conversion material, then wavelength conversion function is achieved, but aging stability and temperature/light resistance are low
Solution Approach 1:
The patent changes the chemical composition parameters of the matrix material by incorporating specific metal oxides (Bi2O3, ZnO, B2O3) in controlled amounts to improve aging stability and temperature resistance while maintaining manufacturability through established ceramic processing techniques
Solution Approach 2:
The patent creates a composite matrix material combining traditional ceramic components with additional metal oxides (Bi2O3, ZnO, B2O3) to achieve enhanced aging stability and temperature/light resistance while maintaining the wavelength conversion functionality through embedded conversion material particles
2Ease of manufacture
If conventional production methods are used for conversion elements, then manufacturing is achieved, but cost-effectiveness is poor
Solution Approach 1:
The patent combines multiple functions into a single manufacturing process by simultaneously forming the matrix material and embedding conversion material particles in one sintering step, eliminating separate processing steps and reducing overall manufacturing cost
Solution Approach 2:
The patent enables the matrix material to self-encapsulate the conversion material particles during the sintering process, eliminating the need for separate encapsulation steps and reducing manufacturing complexity and cost
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 method produces a conversion element with high temperature and light resistance, ensuring long-term stability and cost-effectiveness, suitable for optoelectronic components like LEDs that emit blue, green, red, or white light.
Implementation Method 1
Adding a silicate solution with a viscosity of 2 to 10000 poise to the mixture produced in step B) such that the pH during the addition in step C) is less than 2, obtaining a precipitate comprising the conversion material and silicon dioxide as a matrix material
Implementation Method 2
Washing the precipitate with a washing medium having a pH of less than 2
Implementation Method 3
Hardening the precipitate to produce the conversion element
Data Source
Figure 1A~1F
Figure 2A~2C
Figure 3A~3F
AI summary
The invention relates to a method for producing a conversion element (100) for an optoelectronic component (110) having the following steps: A) providing an acidic medium (1) with a pH value of less than 2, B) adding a conversion material (2) into the acidic medium (1), C) adding a silicate solution (3) with a viscosity of 2 to 10000 P to the mixture produced in step B) such that the pH value during the addition process in step C) is less than 2, wherein a precipitation (4) is obtained which comprises the conversion material (2) and silicon dioxide (41) as the matrix material, D) separating the precipitation (4), E) washing the precipitation (4) using a washing medium (6), said washing medium (6) having a pH value of less than 2, and F) curing the precipitation (4) in order to produce the conversion element (100).