Phosphor Paste Homogeneity via Non-Curable Silicone Suspension

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Solution Overview

Problem

The challenge lies in providing a consistent phosphor product for white light emitting diodes (LEDs) as the storage and transportation of phosphor particles can cause separation and settling, leading to inconsistencies in light emission, which is difficult for manufacturers to overcome without specialized equipment or expertise.

Innovation Solution

A photoluminescence material paste comprising a mixture of inorganic photoluminescence materials and a non-curable silicone fluid is developed, which can be mixed with a curable silicone material to form a compound that reduces clumping and settling of phosphor particles, ensuring consistent light emission and extending shelf life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If phosphor particles are provided as a dry mixture, then the phosphor product can be stored and transported, but separation and settling occur during storage and transportation causing mixture inconsistencies

Engineering Contradiction:

Improvemixture consistencyVSAvoidstorage duration

Core Design Contradiction:

Stability of the object's compositionVSDuration of action of stationary object

Solution Approach 1:

A viscous carrier material is introduced as an intermediary substance to suspend the phosphor particles. This carrier material prevents direct particle-to-particle contact and eliminates settling by providing a medium with sufficient viscosity to maintain particle suspension during storage and transportation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The physical state of the phosphor product is changed from a dry powder mixture to a viscous paste formulation. By changing the viscosity parameter of the carrier material and the loading percentage of phosphor particles, the mixture maintains homogeneity without settling during storage.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If individual phosphors are provided for customer blending, then mixture inconsistencies during storage are avoided, but customers lack the equipment or expertise to achieve consistent distributions

Engineering Contradiction:

Improvemixture consistencyVSAvoidblending ease

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The phosphor particles are pre-mixed in the desired ratios and suspended in the viscous carrier material during manufacturing. This preliminary mixing action eliminates the need for customers to perform blending operations, as the product arrives ready-to-use with the correct phosphor distribution already established.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The viscous carrier material serves as a mediator that maintains the pre-established phosphor mixture ratios. The high viscosity prevents particle segregation during storage and handling, ensuring that the pre-mixed formulation remains consistent without requiring customer blending equipment or expertise.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If curable silicone material is used as carrier, then the phosphor paste can be cured to form a stable structure, but premature curing may occur during storage reducing shelf life

Engineering Contradiction:

Improvestructural stabilityVSAvoidshelf life

Core Design Contradiction:

Stability of the object's compositionVSDuration of action of stationary object

Solution Approach 1:

The curing agent is extracted or separated from the carrier material formulation. By using a non-curable or slowly curable silicone material as the carrier, the curing reaction is delayed or prevented during storage. The carrier material provides structural stability without undergoing premature curing, thereby extending shelf life.

Inventive Principle:

Principle #2Taking out (Extraction)

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 effectively reduces clumping and separation of phosphor particles, ensuring consistent light emission and extending the shelf life of the phosphor product, making it easier for manufacturers to achieve desired color temperatures without requiring advanced equipment or expertise.

Implementation Method 1

a phosphor that is a photoluminescence material, which absorbs a portion of the radiation emitted by the LED and re-emits radiation of a different color (wavelength)

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Data Source

PatentUS9318670B2Materials for photoluminescence wavelength converted solid-state light emitting devices and arrangements

Publication Date: 2016.04.19 INTEMATIX CORP

AI summary

A photoluminescence material paste comprises: a first inorganic photoluminescence material having a first density, a second inorganic photoluminescence material having a second density and a light transmissive non-curable silicone fluid that is not curable by itself. The first density of the first inorganic photoluminescence material is different from the second density of the second inorganic photoluminescence material. The first and second inorganic photoluminescence materials are substantially homogenously distributed within the light transmissive non-curable silicone fluid to form the photoluminescence material paste. A weight loading of the first and second photoluminescence materials in the photoluminescence material paste is in a range of about 60% to about 95%.