Fluorescent Substance Composite Glass Production via Slurry Casting
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Solution Overview
Problem
Existing fluorescent substance composite glasses face issues with chemical stability, large size and uniform thickness production, and low energy conversion efficiency due to low-melting point glass deterioration and molding limitations.
Innovation Solution
A fluorescent substance composite glass is produced by baking a mixture of glass powder and inorganic fluorescent substance powder, with a laminating process using a non-reactive restricting member to achieve a uniform thickness, large size, and high energy conversion efficiency, and the glass composite is characterized by an energy conversion efficiency of 10% or more in the visible light wavelength region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If non-lead type low-melting point glass (SnO2-P2O5 or TeO type) is used to disperse fluorescent substance, then the glass can be molded at low temperature, but the glass has low weatherability and reacts strongly with fluorescent substance causing product deterioration
Solution Approach 1:
The patent changes the chemical composition parameters of the glass, specifically using lead oxide (PbO) in controlled amounts (5-50 mass%) combined with boric oxide (B2O3) and silica (SiO2) to achieve both low melting temperature and high chemical stability. This parameter optimization resolves the contradiction between low-temperature moldability and chemical stability.
Solution Approach 2:
The patent creates a composite glass system combining multiple oxides (PbO, B2O3, SiO2, and others) to achieve properties that individual components cannot provide alone. The composite composition enables both low melting point and high chemical stability, resolving the contradiction between moldability and reliability.
2Shape
If fluorescent substance composite glass is produced by molding glass powder and inorganic fluorescent substance powder under pressure and baking, then glass can be formed, but no glass having low wall thickness can be obtained and large size uniform thickness glass cannot be produced at low costs
Solution Approach 1:
The patent prepares a slurry mixture of glass powder, inorganic fluorescent substance powder, and organic binder beforehand, then forms it into a green sheet with desired thickness and shape before baking. This preliminary forming action enables precise thickness control and large size production at low cost, avoiding the limitations of pressure molding.
Solution Approach 2:
The patent replaces the mechanical pressure molding system with a slurry casting system using organic binder. This substitution allows for easier formation of large-area, uniform-thickness glass products without requiring high-pressure equipment, reducing manufacturing complexity and cost.
3Power
If mold resin is used to seal LED chip and disperse fluorescent substance, then wavelength conversion can be carried out, but the mold resin is deteriorated by high power short-wavelength light causing discoloration
Solution Approach 1:
The patent uses inorganic fluorescent substances embedded in glass that are highly resistant to photodegradation compared to organic mold resins. These inorganic components can withstand high power short-wavelength light without discoloration, providing a durable alternative to deteriorating organic materials.
Solution Approach 2:
The patent creates a composite structure where inorganic fluorescent substances are dispersed in an inorganic glass matrix, replacing the organic mold resin system. This inorganic-inorganic composite provides superior resistance to light-induced deterioration while maintaining wavelength conversion functionality.
4Power
If glass powder and inorganic fluorescent substance powder are molded under pressure and baked, then fluorescent substance composite glass can be obtained, but the energy conversion efficiency is low due to inability to achieve low wall thickness
Solution Approach 1:
The patent forms the green sheet with precisely controlled thin thickness before baking, enabling the final glass product to achieve low wall thickness. This preliminary forming action allows optimization of light transmission and energy conversion efficiency that cannot be achieved through pressure molding of pre-mixed powders.
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 enables the production of chemically stable, low-thickness, and large-sized fluorescent substance composite glass with high energy conversion efficiency, reducing shrinkage and deformation, and maintaining mechanical strength.
Implementation Method 1
a fluorescent substance powder is blended in, for example, a mold resin made of an organic type binder resin that seals a luminous plane of an LED chip to mold and a part or all of the emission from the LED chip is absorbed to carry out conversion into a desired wavelength
Implementation Method 2
baking a mixture containing a glass powder and an inorganic fluorescent substance powder
Data Source
AI summary
The present invention provides a fluorescent substance composite glass which is chemically stable, has a large size, is reduced in wall thickness, has a uniform thickness and therefore has a high energy conversion efficiency; a fluorescent substance composite glass green sheet and a process for producing the fluorescent substance composite glass. The fluorescent substance composite glass of the present invention is produced by baking a mixture containing a glass powder and an inorganic fluorescent substance powder, in which the energy conversion efficiency to a visible light wavelength region of 380 to 780 nm is 10% or more, when light having an emission peak in a wavelength range of 350 to 500 nm is applied.