CN1180489C - 发光二极管及其制造方法 - Google Patents
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Abstract
本发明是提供一种发光二极管及其制造方法，该发光二极管包括无机物型的荧光体、含硅化合物及有机物型的胶体，其中该含硅化合物的化学式的一端可全部或部份为C1-C6烷氧基与该荧光体结合，其结合方式是将该荧光体与含硅化合物在酒精水溶液中混合，并经超声波震荡及加热处理后，使该荧光体与该烷氧基反应结合，形成表面改质型荧光体，而该含硅化合物的化学式的另一端则为环氧基、C1-C6烷基、苯基或氨基的官能基与该胶体结合。借此，经表面改质后的荧光体可均匀分散于该胶体中，不易产生沉淀，使制程稳定，并提高优良率及密着性。
Description
技术领域
本发明涉及一种发光二极管及其制造方法，特别是涉及一种将无机物型的荧光体表面进行改质后，容易与有机物型的胶体混合，不易产生沉淀，以提高制程的稳定度及优良率的发光二极管。
背景技术
按照日本日亚公司，其是以蓝色发光二极管(以氮化铟镓材料为主)激发黄色无机荧光体，该无机荧光体以钇铝石榴石(Yttrium AluminumGarnet；YAG)材质为主，经由黄光与蓝光混合，即可产生白光。此白光发光二极管在极低电流如20mA以下时的发光特性，其色温为8000K，可媲美太阳光色的日光灯，而色彩再现性则接近高性能的三波长型的日光灯，目前具有15lm/W的效率，已接近白热灯泡(5lm/W-10lm/W)与日光灯(10lm/W-30lm/W的效率。
此白色发光二极管与传统以三原色(为红、绿、蓝)发光二极管晶粒组成的白色发光二极管组件比较，其构造简单，且可降低原料与制造成本，并且不须担心因个别单色发光二极管劣化而颜色不均匀的问题，且此白色发光二极管为高指向性光源，可应用于汽车仪表板外围装置、液晶板背光源、室内照明、笔记本电脑显示器、扫瞄器、传真机、投影机或手机等光源。
另外，此种白色发光二极管与传统灯泡比较，具有体积小、寿命长、低电压/电流、无热幅射、不含水银等优点，无污染问题，且照明效率佳、省电，因此被公认将成为二十一世纪的照明光源，逐步占有庞大照明市场。
但是，日亚公司所揭示的制程乃利用钇铝石榴石型的黄色荧光体，以适当比例与树脂混合后，搭配蓝光晶粒封装成白色发光二极管，此制程中因钇铝石榴石型的荧光体属无机氧化物类，其与有机物型的树脂不易混合，是因一般有机物易与有机物混合，而无机物易与无机物混合的特性，且两者比重差异大，使荧光体不易悬浮，故如何使无机物型的荧光体得以均匀且稳定地与有机物型的树脂混合，实为重要的技术。
公知的解决方式是采用高粘度的树脂或其它胶体来与荧光体混和，其又可分为无机类型及有机类型，无机类型以硅胶为主，具有较高的粘滞系数，但混和后荧光体的透光性仅为80％，且有些产品并不适用无机类型的树脂，使得选择性较少；另，有机类型则以环氧树脂(epoxy resin)为主，目前厂商已能够提供粘滞系数较高的环氧树脂，虽然其价格较硅胶便宜，但可作业时间较短。
但是，上述采用物理方法，借由提高胶的粘滞系数来改进荧光体的悬浮性，并减缓荧光体的沉淀状况，尚存在有下列缺点：
(1)高粘度的胶虽然能减缓荧光体的沉淀状况，但由于粘度高造成胶与荧光体间不易混合均匀，容易影响制程的稳定性；
(2)高粘度的胶在点胶制程中，由于粘滞系数高，导致胶量不易精确控制，造成制程不稳定以致优良率降低。
故此，将严重影响到其与蓝色发光二极管混色后的效果及品质。
因此，由上可知，选用何种胶体，并不能有效解决问题，且具有诸多不便与缺陷存在，而可待加以改进。
于是，本发明人有感上述缺陷有待改进，乃特潜心研究并配合学理的运用，终于提出一种设计合理且有效改进上述缺陷的本发明。
发明内容
为了改进公知的上述各项缺点，本发明的主要目的是直接将该荧光体进行改质，便能与有机化合物的胶体结合，经由此交链作用可提高该荧光体溶于该树脂的稳定度，降低沉淀率，而提高产品的优良率，增加彼此之间的密着性，且因两者混和均匀可提高发光的亮度。
因此，本发明的首要目的是提供一种发光二极管；
本发明的另一目的是提供所述发光二极管的制造方法。
本发明涉及一种发光二极管，该发光二极管包括无机物型的荧光体、含硅化合物及有机物型的胶体，该含硅化合物的化学式的一端可全部或部分为C1-C6烷氧基，其与该荧光体结合，其结合方式是将该荧光体与含硅化合物在酒精水溶液中混合，并经超声波震荡及加热处理后，使该荧光体与该烷氧基反应结合，形成表面改质型荧光体，该含硅化合物的化学式的另一端为环氧基、C1-C6烷氧基、苯基或氨基的官能基，该有机型的胶体与该表面改质型荧光体中的该含硅化合物的官能基结合；
借此，经表面改质后的荧光体可均匀分散于该胶体中，不易产生沉淀。
按照本发明所述的发光二极管，其中所述的荧光体为钇铝石榴石(YAG)、氧化物、硫化物或磷酸盐化合物的材质；
其中所述的C1-C6烷氧基为甲氧基或乙氧基；
其中所述的胶体为环氧树脂(epoxy resin)、酚醛树脂(phenolic resin)、聚氨酯树脂(polyurethane resin)、氨基树脂(amino resins)或聚酯树脂(polyester resin)的材质。
本发明还涉及一种发光二极管的制造方法，其包括下列步骤：
(a)提供无机物型的荧光体；
(b)将该荧光体与化学式的一端具有烷氧基的含硅化合物在酒精水溶液中混合，并经超声波震荡及加热处理后，使该荧光体与该含硅化合物的烷氧基反应结合，先形成进行表面改质型荧光体；以及
(c)将表面改质型荧光体与有机物型的胶体混合，使表面改质型荧光体均匀分散于该胶体中，不易产生沉淀。
按照本发明所述的发光二极管的制造方法，其中所述的步骤(a)的荧光体可为钇铝石榴石、氧化物、硫化物或磷酸盐化合物的材质；
其中所述步骤(b)的该含硅化合物的化学式的一端的烷氧基为C1-C6烷氧基，另一端为环氧基、C1-C6烷基、苯基或氨基的官能基；
其中所述的C1-C6烷氧基可为甲氧基或乙氧基；
其中所述的步骤(c)的胶体可为环氧树脂、酚醛树脂、聚氨酯树脂、氨基树脂或聚酯树脂的材质；
其中所述步骤(c)将表面改质型荧光体与有机物型的胶体混合，是使该表面改质型荧光体的该含硅化合物的官能基与该有机物型的胶体结合，且加以搅拌。
为了能更进一步了解本发明为达到预定目的所采取的技术、手段及功效，请参见以下有关本发明的详细说明与附图，相信本发明的目的、特征与特点，当可由此得到深入且具体的了解，然而所述附图仅提供参考与说明用，井非用来对本发明加以限制。
附图说明
图1是本发明发光二极管的结构图；
图2是本发明的波形比较图。
具体实施方式
请参见图1所示，本发明是一种发光二极管及其制造方法，其发光二极管1包括无机物型的荧光体11、含硅化合物12及有机物型的胶体13，其中，该荧光体11可为钇铝石榴石、氧化物、硫化物或磷酸盐化合物等，该含硅化合物12的化学式的一端可全部或部份为C1-C6烷氧基121，与该荧光体11结合，使该荧光体11表面进行改质，且该C1-C6烷氧基可为甲氧基或乙氧基，优选为甲氧基，该含硅化合物12的化学式的另一端则为环氧基、C1-C6烷基、苯基或氨基的官能基122与该胶体13结合，其中优选为环氧基，如此，经表面改质后的荧光体11可均匀分散于该胶体13中，不易产生沉淀，使制程稳定且提高优良率；又，该胶体13可为环氧树脂、酚醛树脂(phenolic resin)、聚氨酯树脂(polyurethaneresin)、氨基树脂(amino resins)或聚酯树脂(polyester resin)等。
如表一所示，将荧光体11采用钇铝石榴石荧光体，含硅化合物12采用含硅的烷氧型化合物(如γ-环氧丙醇丙基二甲氧基甲基硅烷(γ-glycidoxypropyl(dimethoxy)methylsilane)及有机物型的胶体13采用环氧树脂以作为本发明的实施例。
表一：
由于钇铝石榴石荧光体的表面与空气中的水分子接触，易带有氢氧基存于其粉体的表面，故将其与含硅的烷氧型化合物进行改质，则钇铝石榴石荧光体表面的氢氧基易与含硅的烷氧基作用，即烷氧基易离去，使得氢氧基的氧与硅结合，而形成钇(或铝)-氧-硅的键结的表面改质化合物，此键结为一共价键，为一强键结，故可将属无机物型的钇铝石榴石荧光体与此含硅的烷氧基化合物紧密结合。
上述改质的详细制程是为将2克的钇铝石榴石荧光体与0.15克的含硅的烷氧型化合物混于含100毫升的95％容积的酒精水溶液中，将此混合溶液置于超音波震荡10分钟后，再将其于70℃下受热1小时，其后将此溶液的沉淀物过滤掉，以乙醇清洗之，再于85℃干燥，即可得表面改质的钇铝石榴石荧光体粉末。
另，此含硅的烷氧型化合物的化学式的另一端为可溶于有机物型的官能基，若将此经表面改质的化合物与环氧树脂混合，可非常容易地与环氧树脂混合。
故此，经由此交链作用可提高钇铝石榴石荧光体溶于环氧树脂的稳定度，降低沉淀率，而提高产品的优良率，且因两者混和均匀可以提高发光的亮度。
再者，将未改质的钇铝石榴石荧光体与经改质的钇铝石榴石荧光体各取2克，分别置于含10毫升环氧树脂的量筒内，经均匀混合后，量取其随时间变化所产生沉淀的高度，所得的结果如图2所示，当6.5小时过后，经改质的钇铝石榴石粉体产生的沉淀高度为1mm(图中实线处)，仅为未改质的钇铝石榴石粉体沉淀高度2mm的一半(图中虚线处)，而一般产生沉淀愈多即代表混合不稳定且均匀效果差，故，由本实验可证实经本发明所得的表面改质后钇铝石榴石荧光体与环氧树脂混合的效果可有效地增加，且经表面改质后的钇铝石榴石荧光体较易均匀分散。
此外，将未改质的钇铝石榴石荧光体与经改质的钇铝石榴石荧光体，分别与环氧树脂混合后，搭配蓝光晶粒封装成白光发光二极管，经实际测试其白光发光亮度后，证实经改质的钇铝石榴石荧光体，因其与环氧树脂可均匀混合，故亮度较未改质的钇铝石榴石荧光体高4-6％。
据此，经表面改质后的无机物型的荧光体11易于有机物型的胶体13中均匀分散与混合，不易产生沉淀，可提高制程的稳定性，并进而提高优良率，以达到降低成本的目的：再者，因交链作用，可增加彼此之间的密着性，提高信赖度，不易让水渗入。
以上所述，仅为本发明最佳之一的具体实施例的详细说明与附图，但本发明的特征并不局限于此，并非用以限制本发明。凡符合于本发明的精神和与其类似变化的实施例，皆应包含于本发明的范畴中，任何本领域熟练的技术人员，可轻易思及的变化或修饰皆可涵盖在本发明专利范围内。
Claims (10)
1、一种发光二极管，其包括：
无机物型的荧光体；
含硅化合物，该含硅化合物的化学式的一端可全部或部分为C1-C6烷氧基，其与该荧光体结合，其结合方式是将该荧光体与含硅化合物在酒精水溶液中混合，并经超声波震荡及加热处理后，使该荧光体与该烷氧基反应结合，形成表面改质型荧光体；该含硅化合物的化学式的另一端为环氧基、C1-C6烷氧基、苯基或氨基的官能基，以及
有机物型的胶体，其与该表面改质型荧光体中的该含硅化合物的官能基结合；
借此，经表面改质后的荧光体可均匀分散于该胶体中。
2、如权利要求1所述的发光二极管，其特征在于，所述的荧光体为钇铝石榴石、氧化物、硫化物或磷酸盐化合物的材质。
3、如权利要求1所述的发光二极管，其特征在于，所述的C1-C6烷氧基为甲氧基或乙氧基。
4、如权利要求1所述的发光二极管，其特征在于，所述的胶体为环氧树脂、酚醛树脂、聚氨酯树脂、氨基树脂或聚酯树脂的材质。
5、一种发光二极管的制造方法，其包括下列步骤：
(a)提供无机物型的荧光体；
(b)将该荧光体与化学式的一端具有烷氧基的含硅化合物在酒精水溶液中混合，并经超声波震荡及加热处理后，使该荧光体与该含硅化合物的烷氧基反应结合，先形成表面改质型荧光体；以及
(c)将表面改质型荧光体与有机物型的胶体混合，使表面改质型荧光体均匀分散于该胶体中。
6、如权利要求5所述的发光二极管的制造方法，其特征在于，所述的步骤(a)的荧光体可为钇铝石榴石、氧化物、硫化物或磷酸盐化合物的材质。
7、如权利要求5所述的发光二极管的制造方法，其特征在于，所述步骤(b)的该含硅化合物的化学式的一端的烷氧基为C1-C6烷氧基，另一端为环氧基、C1-C6烷基、苯基或氨基的官能基。
8、如权利要求7所述的发光二极管的制造方法，其特征在于，所述的C1-C6烷氧基为甲氧基或乙氧基。
9、如权利要求5所述的发光二极管的制造方法，其特征在于，所述的步骤(c)的胶体为环氧树脂、酚醛树脂、聚氨酯树脂、氨基树脂或聚酯树脂的材质。
10、如权利要求7所述的发光二极管的制造方法，其特征在于，所述步骤(c)将表面改质型荧光体与有机物型的胶体混合，是使该表面改质型荧光体的该含硅化合物的官能基与该有机物型的胶体结合，且加以搅拌。
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Effective date of registration: 20131212 Address after: 213166 Wujin high tech Industrial Development Zone, Jiangsu Province, Yang Lake Road, No. 88 Patentee after: LITE-ON TECHNOLOGY (CHANGZHOU) CO., LTD. Patentee after: Lite-On Technology Corporation Address before: Taipei City, Taiwan, China Patentee before: Lite-On Technology Corporation |
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| CX01 | Expiry of patent term |
Granted publication date: 20041215 |
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| CX01 | Expiry of patent term |