Rare Earth Aluminate Ceramic Complex for High-Luminance Conversion
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Solution Overview
Problem
Existing ceramic complexes with fluorescent materials and translucent inorganic materials do not achieve the desired high luminance levels required for applications such as on-vehicle lighting and liquid crystal display devices.
Innovation Solution
A method for producing a ceramic complex by preparing a raw material mixture of first rare earth aluminate fluorescent material particles, oxide particles containing a second rare earth element, and aluminum oxide particles, followed by calcining the mixture at specific temperatures to form integrated crystal phases that enhance light absorption and conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a ceramic complex includes fluorescent material particles and translucent inorganic material particles, then the structure provides wavelength conversion capability, but the luminance is insufficient for high-performance applications
Solution Approach 1:
The patent merges the fluorescent material particles and translucent inorganic material particles into a single integrated ceramic complex through co-sintering. This merging eliminates the need for separate layers or interfaces between different materials, allowing light to propagate more efficiently through the integrated structure, thereby achieving high luminance while simplifying the manufacturing process.
Solution Approach 2:
The patent creates a composite ceramic material by combining rare earth aluminate fluorescent material with aluminum oxide or other translucent inorganic materials at the molecular level during sintering. This composite structure maintains the wavelength conversion properties of the fluorescent material while benefiting from the optical transparency and mechanical strength of the inorganic matrix, resulting in high luminance output.
2Illumination intensity
If multiple types of particles are mixed in the raw material mixture, then the ceramic complex achieves high luminance through integrated crystal phases, but the manufacturing precision required for controlling particle content ratios increases
Solution Approach 1:
The patent specifies precise parameter ranges for particle content ratios (first rare earth aluminate fluorescent material: 5-40 mass%, oxide particles: 0.1-32 mass%) to optimize the formation of integrated crystal phases during sintering. By controlling these compositional parameters within defined ranges, the patent achieves high luminance while providing clear manufacturing guidelines that reduce the burden on manufacturing precision.
Solution Approach 2:
The patent performs preliminary mixing and uniform distribution of particles with different refractive indexes before sintering. This preliminary action ensures that when the ceramic complex is sintered, the particles are already optimally positioned to form integrated crystal phases, reducing the need for post-processing adjustments and simplifying the manufacturing process.
3Use of energy by moving object
If oxide particles containing second rare earth element are added to the raw material mixture, then integrated crystal phases form during calcining to enhance light absorption, but the device complexity increases
Solution Approach 1:
The patent uses oxide particles containing second rare earth elements that serve multiple functions: they act as sintering aids to promote densification, form integrated crystal phases with the fluorescent material to enhance light absorption efficiency, and contribute to the overall structural stability of the ceramic complex. This multi-functionality reduces the need for separate additives or processing steps, thereby simplifying the overall device structure despite the enhanced composition.
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 resulting ceramic complex achieves high luminance by minimizing interfaces between crystal phases, thereby increasing light absorption and wavelength conversion efficiency.
Implementation Method 1
a light emitting device comprising a light emitting diode (LED) or a laser diode (LD) and a wavelength conversion member including a fluorescent material for converting the wavelength of light emitted from a light emitting element
Implementation Method 2
obtaining a sintered body by calcining the molded body in a temperature range of 1,550° C. or higher and 1,800° C. or lower
Data Source
AI summary
A method for producing a ceramic complex includes: preparing a raw material mixture that contains 5% by mass or more and 40% by mass or less of first rare earth aluminate fluorescent material particles containing an activating element and a first rare earth element different from the activating element, 0.1% by mass or more and 32% by mass or less of oxide particles containing a second rare earth element, and the balance of aluminum oxide particles, relative to 100% by mass of the total amount of the first rare earth aluminate fluorescent material particles, the oxide particles, and the aluminum oxide particles; preparing a molded body of the raw material mixture; and obtaining a sintered body by calcining the molded body in a temperature range of 1,550° C. or higher and 1,800° C. or lower.