Conversion Element Al2O3 Single Crystals Thermal Conductivity
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Solution Overview
Problem
Existing light emitting devices face challenges with heat dissipation due to conversion elements with low thermal conductivities, which affects their optical performance, especially in high power LED and LASER applications.
Innovation Solution
A manufacturing process for conversion elements involving the sintering of lutetium, aluminum, and a rare-earth element at temperatures above 1720°C to form Al2O3 single crystals, which enhances thermal conductivity and optical performance without the need for additional polycrystalline or single crystalline Al2O3 powder, thus improving heat dissipation and light extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sintering processes are used to manufacture conversion elements, then the manufacturing process is simpler and more cost-effective, but the thermal conductivity of the conversion element is low, affecting heat dissipation and optical performance
Solution Approach 1:
The patent changes the sintering temperature parameter to above 1720°C, which is significantly higher than conventional sintering temperatures. This parameter change enables the formation of Al2O3 single crystals within the conversion element, thereby improving thermal conductivity and optical performance without requiring additional Al2O3 powder or complex manufacturing steps
Solution Approach 2:
The conversion element itself generates the Al2O3 single crystals through self-sintering at high temperature. The lutetium, aluminum, and rare-earth element precursors undergo phase transformation during sintering to form the desired crystal structure, eliminating the need for external Al2O3 powder addition or complex multi-step manufacturing processes
2Reliability
If additional Al2O3 powder is added to improve thermal conductivity, then heat dissipation improves, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The conversion element material itself (lutetium, aluminum, and rare-earth element precursors) undergoes phase transformation during high-temperature sintering to generate Al2O3 single crystals internally. This self-service mechanism eliminates the need for adding external Al2O3 powder or performing complex multi-step manufacturing processes while achieving improved thermal conductivity and heat dissipation
Solution Approach 2:
The patent creates a composite structure where Al2O3 single crystals are formed within the conversion element matrix. This composite material approach, achieved through high-temperature sintering of the precursor mixture, results in improved thermal conductivity and heat dissipation properties without requiring separate Al2O3 powder addition steps
3Reliability
If sintering temperature is increased above 1720°C, then Al2O3 single crystals form and thermal conductivity improves, but energy consumption and manufacturing difficulty increase
Solution Approach 1:
The patent changes the sintering temperature parameter to above 1720°C, which is significantly higher than conventional sintering temperatures. This parameter change enables the formation of Al2O3 single crystals within the conversion element, thereby improving thermal conductivity and optical performance without requiring additional Al2O3 powder or complex manufacturing steps
Solution Approach 2:
The conversion element itself generates the Al2O3 single crystals through self-sintering at high temperature. The lutetium, aluminum, and rare-earth element precursors undergo phase transformation during sintering to form the desired crystal structure, eliminating the need for external Al2O3 powder addition or complex multi-step manufacturing processes
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 process results in conversion elements with improved thermal conductivity and optical performance, capable of handling higher photon flux, leading to enhanced efficiency and stability in light emitting devices.
Implementation Method 1
The green body is sintered to obtain the conversion element. The sintering is performed at a temperature of more than 1720° C.
Implementation Method 2
A manufacturing process for conversion elements involving the sintering of lutetium, aluminum, and a rare-earth element at temperatures above 1720°C to form Al2O3 single crystals
Data Source
AI summary
In an embodiment a conversion element includes a first phase and a second phase, wherein the first phase comprises lutetium, aluminum, oxygen and a rare-earth element, wherein the second phase comprises Al2O3 single crystals, and wherein the conversion element comprises at least one groove.