Fluoride Phosphor Manufacturing via Segmented Precipitation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing fluoride phosphors face challenges in controlling particle size and achieving uniform distribution, leading to inefficiencies in quantum efficiency and luminance, particularly in high temperature and humidity environments due to surface fine powder issues.
Innovation Solution
A method involving the preparation of a hydrofluoric solution with specific source materials, including Mn4+, followed by controlled introduction and cleaning processes to form fluoride particles with precise particle size and distribution, and subsequent coating with Mn-free fluoride to enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to manufacture fluoride phosphors, then production is simpler, but particle size control and uniform distribution are poor
Solution Approach 1:
The manufacturing process is segmented into multiple sequential steps: preparing HF solution with first source material and Mn4+, then separately introducing second source material in controlled amounts. This segmentation allows precise control over particle formation stages, enabling better particle size control and uniform distribution compared to conventional single-step methods.
Solution Approach 2:
The HF solution is prepared in advance with specific source materials dissolved before the actual particle formation. This preliminary preparation ensures controlled reaction conditions when the second source material is introduced, leading to more precise particle size control and uniform distribution.
2Reliability
If fluoride phosphors are manufactured without surface treatment, then production is faster, but fine powder on surfaces reduces reliability in high temperature and humidity environments
Solution Approach 1:
Fine powder on the phosphor particle surfaces is removed through cleaning steps involving organic solvents. This extraction of harmful surface contaminants eliminates the source of reliability problems in high temperature and humidity environments, while the process is integrated into the manufacturing workflow to minimize productivity impact.
Solution Approach 2:
Surface cleaning steps are incorporated into the manufacturing process before the phosphors are used or packaged. By removing fine powder beforehand, the phosphors are protected from degradation in harsh environments, cushioning against future reliability issues.
3Ease of manufacture
If particle size is not controlled, then manufacturing is easier, but quantum efficiency and luminance are reduced
Solution Approach 1:
The manufacturing process uses dynamic control of the second source material introduction, adjusting the amount and timing based on desired particle size targets. This dynamic approach maintains ease of manufacture while achieving precise particle size control that optimizes quantum efficiency and luminance.
Solution Approach 2:
Particle size is controlled by changing parameters such as the amount of second source material introduced, the concentration of HF solution, and the sequence of material addition. These parameter changes enable optimization of quantum efficiency and luminance while keeping the manufacturing process relatively simple.
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 achieves improved quantum efficiency, luminance, and reliability of fluoride phosphors, enabling their use in various applications, including white light emitting apparatuses, with enhanced performance in diverse environmental conditions.
Implementation Method 1
preparing a hydrofluoric (HF) solution in which a first source material and a fluoride containing Mn4+ are dissolved
Implementation Method 2
forming fluoride particles by introducing a second source material to the HF solution
Data Source
AI summary
A method of manufacturing a fluoride phosphor, the method comprising: preparing a hydrofluoric (HF) solution in which a first source material and a fluoride containing Mn4+ are dissolved; and forming fluoride particles by introducing a second source material to the HF solution in each of a plurality of instances.