Fluoride Phosphor Particle Sizing for Uniform Thin LED Films
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Solution Overview
Problem
Existing fluoride phosphors, such as KSF, struggle to form smooth and uniform phosphor films, particularly in miniaturized LED applications, where traditional potting methods are inadequate, and coating or printing methods fail to achieve the desired film quality.
Innovation Solution
A fluoride phosphor composition represented by General Formula A2M(1-n)F6:Mn4+n, with specific particle size distribution (D50: 0.1 to 9.5 μm and D90: 0.5 to 16 μm), combined with a sealing material, to facilitate the formation of a smooth and uniform phosphor film with improved optical characteristics and quantum efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional potting method is used to apply fluoride phosphor, then the phosphor can be easily applied to substrate, but the method is not suitable for miniaturized LED applications and cannot form thin uniform films
Solution Approach 1:
The patent changes the particle size parameter of the fluoride phosphor to D50: 0.1 to 9.5 μm and D90: 0.5 to 16 μm, which enables the phosphor to form smooth and uniform thin films when applied by coating or printing methods, making it suitable for miniaturized LED applications
2Volume of moving object
If coating method or printing method is used to form phosphor film, then thin phosphor film can be formed, but the film cannot be sufficiently smooth and uniform with conventional fluoride phosphors
Solution Approach 1:
The patent optimizes the particle size distribution parameters (D50: 0.1 to 9.5 μm, D90: 0.5 to 16 μm) of the fluoride phosphor, which enables the formation of smooth and uniform thin phosphor films through coating or printing methods, resolving the contradiction between film thickness and film quality
3Ease of operation
If fluoride phosphor with larger particle size is used, then the phosphor can be easily handled and applied, but the phosphor film becomes rough and non-uniform
Solution Approach 1:
The patent establishes an optimal particle size range (D50: 0.1 to 9.5 μm, D90: 0.5 to 16 μm) that balances ease of handling with the ability to form smooth and uniform phosphor films, allowing the phosphor to be effectively used in miniaturized LED applications
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 proposed fluoride phosphor composition enables the formation of smooth and uniform films with high quantum efficiency, suitable for micro-LEDs, mini-LEDs, and wavelength conversion elements, while maintaining excellent optical properties and preventing excessive blue light transmission.
Implementation Method 1
a complex that converts a wavelength of the excitation light
Data Source
AI summary
A fluoride phosphor, a composition of which is represented by General Formula (1), in which in a case where a cumulative 50% value is denoted by D50 and a cumulative 90% value is denoted by D90 in a volume-based particle size distribution curve obtained by a laser diffraction scattering method, D50 is 0.1 to 9.5 μm and D90 is 0.5 to 16 μm. General Formula (1): A2M(1-f)F6:Mn4+n In General Formula (1), an element A is one or more alkali metal elements including K, an element M is a Si simple substance, a Ge simple substance, or a combination of Si and one or more elements selected from the group consisting of Ge, Sn, Ti, Zr, and Hf, and 0<n≤0.1 is satisfied.