Narrow-Band Phosphor Ink Composition for Stable LED Printing
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Solution Overview
Problem
Current methods for applying phosphor materials on miniaturized LEDs face challenges due to low quantum efficiency, poor thermal stability, and agglomeration issues with quantum dots, and sedimentation problems with organic solvents in coating and printing processes.
Innovation Solution
A stable ink composition with a binder material and uniformly dispersed narrow band emission phosphors, including green-emitting U6+-containing and Mn2+-containing phosphors, is developed for coating or printing on LEDs, miniLEDs, and microLEDs, using a solvent that prevents sedimentation and agglomeration, enhancing color conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If quantum dot materials are used in ink jet printable ink, then strong absorption coefficient is achieved, but low quantum efficiency and poor thermal stability significantly limit practical applications
Solution Approach 1:
The patent changes the material parameters from quantum dots to phosphor materials with optimized particle size (0.1-15 μm) and composition (U6+-containing green-emitting phosphors, Mn2+-containing green-emitting phosphors, Mn4+-activated red-emitting complex fluoride phosphors). This parameter change maintains strong absorption while improving quantum efficiency and thermal stability for practical LED applications
Solution Approach 2:
The patent uses composite phosphor formulations combining multiple phosphor types (green-emitting U6+-containing phosphors, green-emitting Mn2+-containing phosphors, and red-emitting Mn4+-activated complex fluoride phosphors) to achieve both strong absorption and high reliability, resolving the contradiction between absorption coefficient and quantum efficiency/stability
2Length of moving object
If phosphor materials with small particle sizes are used for miniaturized LEDs, then coating and printing processes are enabled, but agglomeration occurs when mixed with commonly used solvents
Solution Approach 1:
The patent introduces a specifically designed solvent system as an intermediary between the phosphor particles and the final coating. This solvent prevents agglomeration of small particle size phosphors (0.1-15 μm) during mixing and processing, maintaining dispersion stability while enabling the use of small particles for miniaturized LED applications
Solution Approach 2:
The patent changes the solvent parameters from commonly used solvents to a specifically formulated solvent system that is compatible with small particle size phosphors. This parameter change prevents agglomeration and sedimentation, enabling stable dispersions of fine phosphor particles for ink jet and other coating processes
3Ease of manufacture
If phosphor materials are used with organic solvents in coating processes, then printing and coating compositions are formed, but sedimentation occurs which is undesirable for subsequent processes
Solution Approach 1:
The patent uses a specifically formulated solvent system as an intermediary that prevents sedimentation of phosphor particles during coating and printing processes. This intermediary solvent maintains stable dispersions throughout the manufacturing process, enabling ease of manufacture while preventing the harmful sedimentation effect
Solution Approach 2:
The patent changes the solvent parameters from conventional organic solvents to a specifically designed solvent system with optimized properties. This parameter change eliminates sedimentation while maintaining the processability needed for ink jet printing and other coating methods, resolving the contradiction between ease of manufacture and dispersion stability
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 solution provides high color quality lighting and stable dispersions, improving the performance of miniLED and microLED technologies by maintaining phosphor stability and efficiency during the coating and printing processes.
Implementation Method 1
Narrow band emission phosphor materials achieve high color quality in lighting and displays based on LEDs
Data Source
AI summary
An ink composition is provided. The composition includes a binder material and at least one narrow band emission phosphor being uniformly dispersed throughout the composition, wherein the narrow band emission phosphor has a D50 particle size from about 0.1 μm to about 15 μm and is selected from the group consisting of a green-emitting U6+-containing phosphor, a green-emitting Mn2+-containing phosphor, a red-emitting phosphor based on complex fluoride materials activated by Mn4+, and a mixture thereof. A device is also provided.