Crosslinked Polysiloxane Wavelength Conversion Matrix
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Solution Overview
Problem
Common wavelength conversion elements are not thermally stable, expensive, and difficult to combine multiple phosphors into a single conversion layer, limiting their application and efficiency.
Innovation Solution
A wavelength conversion element comprising a crosslinked matrix with dispersed phosphors, made from a precursor material with specific chemical structures, such as substituted polysiloxane or polysilazane, which is thermally stable, inexpensive to produce, and allows for the incorporation of multiple phosphors, enabling sharper edges, uniform brightness, and controlled color output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If common wavelength converting materials are used, then the conversion element can be produced, but thermal stability above 200°C is not achieved
Solution Approach 1:
The patent changes the chemical composition parameters of the matrix material by using polysiloxane or polysilazane precursors with specific molecular structures and crosslinking densities. This chemical parameter change enables the matrix to maintain structural integrity and optical properties at temperatures above 200°C, resolving the thermal stability issue while preserving reliability
Solution Approach 2:
The patent creates a composite material system combining inorganic phosphor particles with an organic-inorganic hybrid crosslinked matrix. This composite structure leverages the high thermal stability of the crosslinked polysiloxane/polysilazane network while incorporating phosphors for wavelength conversion, achieving both thermal stability and functional reliability at elevated temperatures
2Adaptability or versatility
If multiple wavelength converting materials are combined, then color versatility is improved, but production cost and complexity increase
Solution Approach 1:
The patent merges multiple wavelength converting phosphors into a single conversion layer within one matrix material. This consolidation allows different phosphors (e.g., for blue, green, red conversion) to be simultaneously incorporated and processed together, achieving color versatility while simplifying the production process by eliminating the need for separate layers or complex assembly steps
Solution Approach 2:
The patent develops a universal matrix material platform (crosslinked polysiloxane or polysilazane) that can accommodate various types of phosphors and enable different color output configurations. This multi-functional matrix system can be tuned for different applications by simply changing the phosphor composition, rather than requiring different matrix materials or production processes for each color variant
3Ease of manufacture
If standard silicone matrix is used, then ease of manufacture is maintained, but edge sharpness and surface quality deteriorate
Solution Approach 1:
The patent changes the rheological and curing parameters of the matrix material by using crosslinking chemistry in polysiloxane or polysilazane precursors. This results in materials with optimized viscosity and cure characteristics that enable sharp edge definition and smooth surfaces during molding or casting processes, while maintaining ease of manufacture through simple processing steps
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 a thermally stable, cost-effective wavelength conversion element with improved edge quality and color uniformity, enabling the production of various colors and blends, including cool and warm-white light, by using a highly crosslinked matrix that can be processed at room temperature or slightly elevated temperatures without solvents.
Implementation Method 1
a crosslinked matrix and at least one phosphor dispersed in that matrix, wherein the matrix is made from a precursor material
Implementation Method 2
at least one phosphor dispersed in that matrix... absorbs electromagnetic radiation within a certain first range of wavelengths and then emits radiation having a second range of wavelengths
Data Source
AI summary
A wavelength conversion element comprising a crosslinked matrix and at least one phosphor dispersed in said matrix, wherein said matrix is made from a precursor material comprising a precursor having a structure chosen from one of the generic formulaeis provided. Further, a light emitting device comprising a wavelength conversion element and a method for producing a wavelength conversion element are provided.