Nanophosphor Converter Material Sedimentation and Brightness
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Solution Overview
Problem
Conventional wavelength-converting reaction resin masses face issues such as reduced brightness, processing problems, and quantum yield losses due to large phosphor particle sizes, sedimentation, and surface interactions, which affect the quality and efficiency of light-emitting diode components.
Innovation Solution
A wavelength-converting converter material using phosphor nanoparticles with median diameters of less than 100 nm, combined into agglomerates, and optionally combined with inorganic materials like glass or transparent conductive oxides, to enhance homogeneity and emission characteristics, while eliminating the need for optically inactive sedimentation retarders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If large phosphor particles (d50: 10-20 μm) are used in the reaction resin composition, then sedimentation is prevented, but brightness is reduced and processing problems occur
Solution Approach 1:
The patent changes the particle size parameter of phosphor from conventional large particles (d50: 10-20 μm) to fine grains (d50 < 1 μm), specifically 0.1-10 μm, to simultaneously achieve good sedimentation resistance and high brightness. This parameter optimization resolves the contradiction between preventing sedimentation and maintaining brightness.
2Productivity
If the proportion of phosphor in the reaction resin mass is increased, then conversion efficiency is improved, but surface interactions cause turbidity and optical quenching
Solution Approach 1:
The patent changes the particle size parameter of phosphor to fine grains (d50 < 1 μm), which reduces surface interactions and prevents turbidity and optical quenching even at high phosphor concentrations. This enables increased phosphor proportion for improved conversion efficiency without sacrificing brightness.
3Stability of the object's composition
If optically inactive sedimentation retarders (e.g., Aerosil) are added to prevent sedimentation, then phosphor sedimentation is reduced, but brightness decreases
Solution Approach 1:
The patent extracts and eliminates the optically inactive sedimentation retarders (e.g., Aerosil) from the reaction resin composition. By using inherently sedimentation-resistant fine grain phosphor particles (d50: 0.1-10 μm), the patent achieves sedimentation prevention without adding substances that reduce brightness.
4Ease of manufacture
If phosphor particles with unfavorable shapes (splintered, angular) are used, then manufacturing is simplified, but light coupling losses increase and quantum yield is reduced
Solution Approach 1:
The patent changes the shape parameter of phosphor particles from unfavorable shapes (splintered, angular) to favorable shapes (spherical, regular) with smooth surfaces. This shape optimization reduces light coupling losses and improves quantum yield while remaining compatible with standard phosphor production methods.
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 use of nanoparticles in the converter material improves the homogeneity of the luminous image, reduces sedimentation, and increases the conversion efficiency, enabling high-quality, stable, and reproducible light emission with precise color locus control, suitable for light-emitting diode components.
Implementation Method 1
A wavelength-converting converter material, in particular a reaction resin mass to which at least one phosphor has been added, wherein part or all of the phosphor is present in the form of nanoparticles
Data Source
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AI summary
A wavelength-converting converter material is specified which has at least one wavelength-converting phosphor with phosphor particles, part of the phosphor or the entire phosphor being present in the form of nanoparticles. A light-emitting optical component comprising a converter material of this type and a method for the production of components of this type are additionally specified.