Wavelength Converting Component Using Ceramizable Silazane Matrix
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current matrix materials for embedding wavelength converting materials in LEDs face challenges such as poor barrier properties, thermal stability, mechanical stability, and compatibility with various wavelength converting materials, particularly under high temperature and radiation conditions, leading to issues like degradation, discolouration, and limited shape complexity.
Innovation Solution
A method involving a dispersion of crosslinkable ceramizable materials with silazane repeating units, cured at temperatures between 250°C to 500°C, forming a semi-ceramic matrix with Si—N bonds, which provides improved thermal conductivity, mechanical stability, and compatibility with various wavelength converting materials, allowing for complex shapes and enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If ceramic platelets are used as wavelength converting components, then thermal stability is improved, but manufacturing difficulty increases and shape complexity is limited
Solution Approach 1:
The invention changes the manufacturing parameters from high-temperature sintering (>1000°C) to low-temperature curing (250-500°C) by using crosslinkable ceramizable materials. This parameter change enables thermal stability comparable to ceramics while dramatically simplifying the manufacturing process and allowing complex geometries to be achieved through molding techniques.
Solution Approach 2:
The invention uses composite materials consisting of crosslinkable ceramizable materials combined with wavelength converting materials. This composite approach provides the thermal stability of ceramic materials while maintaining the ease of manufacture and shape flexibility of polymer-based materials, resolving the contradiction between thermal performance and manufacturing complexity.
2Stability of the object's composition
If high sintering temperatures are used for ceramic platelets, then thermal stability is improved, but compatibility with certain wavelength converting materials deteriorates due to decomposition
Solution Approach 1:
The invention changes the processing temperature parameter from high-temperature sintering (>1000°C) to low-temperature curing (250-500°C). This parameter change preserves the thermal stability of the final product while preventing thermal decomposition of sensitive wavelength converting materials such as silicate and nitride phosphors during manufacturing, thereby improving material compatibility.
3Ease of manufacture
If conventional binder materials are used for embedding wavelength converting material, then ease of manufacture is improved, but thermal stability deteriorates due to decomposition under high temperature
Solution Approach 1:
The invention replaces conventional organic binder materials with crosslinkable ceramizable materials that form a semi-ceramic matrix upon curing. This composite material approach maintains the ease of manufacture associated with binder-based systems while achieving the thermal stability of ceramic materials, as the cured matrix can withstand high temperatures without decomposition.
4Stability of the object's composition
If ceramic platelets are used, then thermal stability is improved, but shape complexity is limited to plain geometries
Solution Approach 1:
The invention changes the processing method from sintering (which limits shape complexity) to molding and curing processes. This parameter change enables the production of wavelength converting components with complex geometries including protrusions and recesses, while maintaining the thermal stability achieved through the ceramizable material 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 solution achieves stable colour point conversion of blue, violet, and UV light to longer wavelengths with improved thermal conductivity and mechanical stability, maintaining performance under high power LED conditions without thermal decomposition or discolouration, and allows for complex geometries and broad compatibility with wavelength converting materials.
Implementation Method 1
curing said dispersion at a temperature of >250 to ≤500° C. to obtain a wavelength converting component
Implementation Method 2
a crosslinkable ceramizable material and at least one wavelength converting material... curing said dispersion... to obtain a wavelength converting component
Implementation Method 3
The wavelength converting component of the present invention can be used for converting blue, violet and/or UV light into light with a longer wavelength
Data Source
AI summary
The present invention relates to a manufacturing method for a wavelength converting component which is prepared from a dispersion containing a crosslinkable ceramizable polymer material having a silazane repeating unit and at least one wavelength converting material. There are further provided wavelength converting components which can be used for converting blue, violet and/or UV light into light with a longer wavelength. There is also provided a light source and a lighting unit comprising said wavelength converting components.