Sulfur-Containing Phosphor Metal Borate Barrier Layer
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Solution Overview
Problem
Sulfur-containing phosphors in white LED elements face issues with hydrogen sulfide gas generation, leading to inhibition of silicone resin curing, corrosion of metal components, and electrical failures, which existing coatings like glass or ZnO fail to adequately address, especially under long-term reliability tests.
Innovation Solution
A sulfur-containing phosphor configuration featuring crystalline metal borate particles or layers containing IIA-Group elements, zinc, boron, and oxygen, either directly on the phosphor surface or within a glass coating layer, effectively absorbs sulfur-based gases, preventing corrosion while maintaining luminescent efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sulfur-containing phosphor is used in white LED element, then various colors of light can be emitted depending on composition, but hydrogen sulfide gas is generated causing inhibition of silicone resin curing, corrosion of metal members, and electrical failure
Solution Approach 1:
A barrier layer comprising a metal borate compound is introduced as an intermediary between the sulfur-containing phosphor particles and the surrounding environment (silicone resin, metal members). This barrier layer mediates the interaction by blocking the diffusion path of hydrogen sulfide gas, preventing it from reaching and damaging the silicone resin and metal members, while allowing the phosphor to maintain its color emission capability
Solution Approach 2:
The invention creates a composite structure where sulfur-containing phosphor particles are coated or surrounded by a barrier layer of metal borate compound. This composite material combines the luminescent properties of the sulfur-containing phosphor with the protective properties of the metal borate compound, achieving both color emission and corrosion prevention
2Use of energy by moving object
If sulfur-containing phosphor is used, then luminescence can be achieved, but corrosion of Ag reflective film occurs leading to decrease in reflection performance
Solution Approach 1:
The metal borate compound barrier layer serves as a protective intermediary between the sulfur-containing phosphor and the Ag reflective film. It blocks the corrosive hydrogen sulfide gas generated by the phosphor from reaching the Ag film, thereby preventing corrosion and maintaining high reflection performance while allowing the phosphor to maintain its luminescence efficiency
3Reliability
If glass coating or ZnO coating is applied to sulfur-containing phosphor, then moisture resistance is enhanced, but sulfur-based gas still causes corrosion of metallic member under long-term reliability test
Solution Approach 1:
The invention creates a multi-layer composite coating structure where a glass coating or ZnO compound layer is combined with a metal borate compound barrier layer. This composite coating provides both moisture resistance (from the glass/ZnO layer) and effective corrosion prevention (from the metal borate layer), solving the limitations of single-layer coatings
Solution Approach 2:
The metal borate compound barrier layer is specifically positioned at the interface where sulfur-based gas generation occurs, providing localized corrosion protection exactly where it is most needed, while the outer glass or ZnO layer provides general moisture resistance
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 crystalline metal borate configuration efficiently inhibits corrosion of metallic members and maintains high brightness by chemically absorbing sulfur-based gases, enhancing moisture resistance and lumen maintenance even under harsh environmental conditions.
Implementation Method 1
both the crystalline metal borate containing an IIA-Group element, boron, and oxygen and the crystalline metal borate containing zinc, boron, and oxygen have a feature of chemically absorbing a sulfur-based gas
Implementation Method 2
Such a sulfur-containing phosphor containing sulfur in a host material is excited by an LED or the like, and can emit various colors of light depending on composition
Data Source
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AI summary
Proposed is a phosphor capable of effectively inhibiting the occurrence of adverse influence of a sulfur-based gas while improving water resistance of the phosphor and effectively inhibiting the corrosion of a metallic member. A phosphor is proposed, which includes particles or a layer provided on the surface of a sulfur-containing phosphor, which contains sulfur in a host material, and containing a crystalline metal borate containing an IIA-Group element, boron, and oxygen.