Nitridophosphate Phosphor Synthesis at Moderate Nitrogen Pressure
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Solution Overview
Problem
The existing methods for synthesizing nitridophosphates, including nitridophosphate phosphors, are limited to small scales and high costs due to the requirement of high ammonia gas pressures and nitrogen pressures exceeding 1 GPa, making them unsuitable for commercial applications.
Innovation Solution
A method for commercial-scale synthesis of nitridophosphate phosphors using a gas pressure furnace with moderate nitrogen pressures (2-300 MPa) and temperatures (800-1300°C), allowing for the production of large quantities of nitridophosphate compounds, such as Ca2PN3:Eu and Sr3P5N10Cl:Eu, using elemental phosphorus as a phosphorus source material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high ammonia gas pressures or nitrogen pressures exceeding 1 GPa are used to synthesize nitridophosphates, then the synthesis can proceed, but the production cost increases and large-scale production becomes unsuitable
Solution Approach 1:
The patent changes the pressure parameter from exceeding 1 GPa to moderate nitrogen pressures of 2-300 MPa, which is a significant reduction in pressure magnitude. This parameter change enables the synthesis to proceed at much lower costs while maintaining synthesis success, directly resolving the contradiction between synthesis reliability and manufacturing ease
2Reliability
If high ammonia gas pressures or nitrogen pressures exceeding 1 GPa are used to synthesize nitridophosphates, then the synthesis can proceed, but the production scale remains small and commercial applications become unsuitable
Solution Approach 1:
The patent implements parameter changes in pressure (from >1 GPa to 2-300 MPa) and temperature (800-1300°C) that enable both synthesis success and large-scale production. The moderate pressure range specifically allows for scalable production without compromising the reliability of nitridophosphate formation, resolving the contradiction between synthesis reliability and productivity
3Productivity
If moderate nitrogen pressures (2-300 MPa) and temperatures (800-1300°C) are used, then large-scale production becomes feasible, but the synthesis conditions differ from traditional methods
Solution Approach 1:
The patent establishes specific parameter ranges (nitrogen pressure: 2-300 MPa, temperature: 800-1300°C) that optimize both production scale and process simplicity. These defined parameters create a standardized synthesis process that is easier to control and scale up compared to traditional high-pressure methods, resolving the contradiction between productivity and device complexity
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
This method enables the cost-effective large-scale production of nitridophosphate phosphors, significantly reducing production pressures and costs, enabling their commercial use in phosphor-converted LEDs, with successful synthesis of up to 12 kg in a single batch.
Implementation Method 1
a method for commercial-scale production of nitridophosphates, involving the combination of precursor materials and their synthesis under moderate nitrogen pressures (2-300 MPa) and temperatures (800-1300°C) in a gas pressure furnace
Data Source
AI summary
A method of forming a nitridophosphate is disclosed, the method including forming a precursor mixture by combining a metal source material, a phosphorus source material, and a nitrogen source material, and heating the precursor mixture at a maximum temperature between 800° C. and 1300° C. in an atmosphere including nitrogen gas at a pressure between 2 MPa and 500 MPa.