Core-Shell Phosphor for High Brightness White LEDs

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Solution Overview

Problem

Conventional phosphors used in light emitting devices, such as white LEDs, face challenges in achieving high light emission intensity, particularly in optimizing element composition and particle size to enhance brightness and color purity.

Innovation Solution

A core-shell structured phosphor is developed, comprising a crystal phase of an inorganic compound with a metal element acting as a luminescent center ion and aluminum, coated with a shell of boron or silicon, where the shell part is formed on the surface of the core part through a specific heating process, optimizing the composition ratios and shell-to-core ratios to improve light emission efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the phosphor uses conventional crystal structures with optimized element composition, then light emission intensity is improved to some extent, but the light emission intensity is insufficient for high-brightness applications in light emitting devices

Engineering Contradiction:
Improvelight emission intensityVSAvoidbrightness performance
Core Design Contradiction:
Illumination intensityVSReliability

Solution Approach 1:

The patent applies composite materials by creating a core-shell structure where the core is formed from a crystal phase of an inorganic compound containing aluminum and the shell is formed from boron or silicon. This composite structure combines the advantages of different materials: the aluminum-containing crystal provides high light emission intensity while the boron or silicon shell improves color purity and light extraction efficiency, collectively achieving superior brightness performance that conventional single-material phosphors cannot attain

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by creating a core-shell structure where different regions of the phosphor particle have different compositions and functions. The core region contains the aluminum-containing crystal phase responsible for high light emission intensity, while the shell region contains boron or silicon that provides color purity and light extraction. This spatial differentiation of material properties allows each region to optimize its specific function, resolving the contradiction between intensity and brightness performance

Inventive Principle:
Principle #3Local quality

2Illumination intensity

If the phosphor particle size is optimized to improve light emission efficiency, then brightness is enhanced, but color purity and internal quantum efficiency are compromised

Engineering Contradiction:
ImprovebrightnessVSAvoidcolor purity
Core Design Contradiction:
Illumination intensityVSStability of the object's composition

Solution Approach 1:

The patent uses composite materials with a core-shell structure where the shell made of boron or silicon acts as a protective layer that maintains color purity while the core aluminum-containing crystal provides high light emission intensity. This composite structure allows the phosphor to achieve both brightness and color purity simultaneously, as the shell prevents spectral broadening and the core maintains high quantum efficiency

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by confining different functional properties to different spatial regions: the core region maintains the crystal structure for high intensity emission while the shell region controls color purity. This spatial separation allows independent optimization of brightness and color purity without compromise

Inventive Principle:
Principle #3Local quality

3Illumination intensity

If the phosphor is used in white LEDs with optimized composition, then light emission intensity is improved, but internal quantum efficiency and light extraction efficiency are insufficient

Engineering Contradiction:
Improvelight emission intensityVSAvoidinternal quantum efficiency
Core Design Contradiction:
Illumination intensityVSLoss of energy

Solution Approach 1:

The patent applies composite materials by creating a core-shell structure where the aluminum-containing crystal core provides high internal quantum efficiency and the boron or silicon shell improves light extraction efficiency. The shell acts as a protective layer that reduces non-radiative recombination and enhances the extraction of generated light, thereby reducing energy loss and improving overall quantum efficiency in white LED applications

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 core-shell structure significantly enhances light emission intensity and color purity by reducing defects and improving the efficiency of light exit, resulting in improved brightness and stability of the phosphor, even when used in white LEDs.

Implementation Method 1

heating the obtained mixture at a temperature at which the raw material of the shell part is liquefied, but a host crystal of phosphor is maintained to be obtained

Methodology Applied
Scientific EffectHeating: Heating

Implementation Method 2

a phosphor having a composition represented by a formula Mn0.15Mg0.54Al3.0O4.4N0.54

Methodology Applied
Scientific EffectPhotoluminescence: Photoluminescence

Data Source

PatentUS20240101895A1Method for producing phosphor and phosphor
Publication Date: 2024.03.28 SUMITOMO CHEM CO LTD

AI summary

A method for producing a phosphor having a core-shell structure that includes: a core part formed of a crystal phase of an inorganic compound containing a metal element M constituting a luminescent center ion and aluminum; and a shell part containing at least one element selected from the group consisting of boron and silicon and formed on at least a portion of a surface of the core part, the method including: mixing a raw material of the crystal phase and a raw material of the shell part; and heating the obtained mixture at a temperature at which the raw material of the shell part is liquefied, but a host crystal of a phosphor to be obtained is maintained, in which the raw material of the crystal phase contains a raw material compound having D50 in a particle diameter distribution of 0.2 to 90 μm and containing aluminum.