Wavelength Conversion Member Using Silane Coupling Agent
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Wavelength conversion devices face issues with phosphor particles falling off during manufacturing, particularly when large-sized or deposited over a large area, leading to reduced yield and efficiency.
Innovation Solution
Incorporating filler particles made of resin material into the matrix, which adhere to both the phosphor particles and the substrate, preventing them from falling off during the manufacturing process and ensuring proper embedding within the matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large-sized phosphor particles are deposited over a large area, then the optical output and brightness are improved, but the phosphor particles fall off during manufacturing
Solution Approach 1:
The patent introduces a silane coupling agent as an intermediary substance between the phosphor particles and the inorganic matrix. This coupling agent forms chemical bonds with both the phosphor particle surfaces and the matrix material, creating a strong intermediate layer that prevents particle detachment. The silane coupling agent specifically reacts with hydroxyl groups on phosphor surfaces and forms covalent bonds with the inorganic matrix, thereby solving the adhesion problem while maintaining large particle size and broad area coverage for high optical output.
Solution Approach 2:
The patent creates a composite structure consisting of phosphor particles, silane coupling agent, and inorganic matrix (such as ZnO). This composite material system combines the light-emitting properties of phosphor with the mechanical strength and chemical stability of the inorganic matrix, while the silane coupling agent provides the bonding interface. The composite structure enables large-sized phosphor particles to be firmly embedded in the matrix over large areas, achieving both high optical output and reliable particle retention.
2Ease of manufacture
If phosphor particles are embedded in a matrix without filler particles, then the manufacturing process is simpler, but the phosphor particles fall off during manufacturing
Solution Approach 1:
The silane coupling agent serves as a chemical intermediary that bridges the phosphor particles and the inorganic matrix. It is applied to the phosphor particle surfaces before matrix formation, where it creates bonding sites that chemically connect to the matrix material. This intermediary layer maintains manufacturing simplicity while fundamentally solving the adhesion problem through chemical bonding mechanisms.
Solution Approach 2:
The patent changes the chemical parameters of the phosphor particle surfaces by treating them with silane coupling agents. This surface modification alters the chemical composition and bonding characteristics of the particle surfaces, enabling strong chemical bonds with the inorganic matrix. The parameter change from simple physical embedding to chemically-bonded embedding achieves reliable particle retention without complicating the overall manufacturing process.
3Manufacturing precision
If the phosphor is heated during manufacturing, then the matrix formation is improved, but the phosphor particles may detach
Solution Approach 1:
The silane coupling agent is applied to the phosphor particles before the matrix formation and heating processes. This preliminary action prepares the particle surfaces with bonding capabilities that will withstand subsequent thermal processing. The coupling agent forms a protective and bonding layer that remains stable during heating, preventing particle detachment while allowing proper matrix formation.
Solution Approach 2:
The silane coupling agent provides beforehand cushioning by creating a chemically-bonded interface between phosphor particles and the matrix before heating occurs. This pre-established chemical bonding acts as a cushioning mechanism that absorbs thermal stresses and prevents particle detachment during the heating process required for matrix formation.
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
This configuration effectively prevents phosphor particle loss, increases the yield of wavelength conversion devices, and maintains high light emission efficiency even after heating, with filler particles providing excellent adhesiveness and heat resistance.
Implementation Method 1
a silane coupling agent which forms a chemical bond with particles of the phosphor and the inorganic matrix
Implementation Method 2
When irradiated with excitation light from the excitation light source, the phosphor emits fluorescence light having a longer wavelength than the excitation light
Data Source
AI summary
A wavelength conversion device includes a matrix containing inorganic material, a phosphor embedded in the matrix, and filler particles embedded in the matrix and containing resin material. This wavelength conversion device prevents the phosphor from falling.