CN1581523A - 波长变换型发光二极管 - Google Patents
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Abstract
波长变换型发光二极管。根据本发明,通过提供一种波长变换型LED,解决了荧光体在粘合剂基材中不产生沉淀的课题,在该波长变换型LED中,发光部由以下部分构成,即:激励元件2,用于发出蓝色光或紫外光;荧光体4,其平均粒径D50大于等于5μm且小于等于20μm,用于把来自该激励元件的发光的至少一部分变换成比激励波长长的波长;分散剂5,其平均粒径D50的值大于等于荧光体的平均粒径D50的1/10;以及粘合剂基材3,其含有上述荧光体和分散剂;使上述荧光体和上述分散剂合计起来的重量大于等于上述粘合剂基材的重量的20wt%小于等于60wt%。
Description
技术领域
本发明涉及一种LED(发光二极管),详细地说,涉及一种LED的结构,该LED设有波长变换单元,用于获得与LED芯片的本来的发光色不同的发光色,例如使用来自LED芯片的蓝色光激励黄色荧光体,获得作为蓝色和黄色的合成色的白色的发光色等。
背景技术
作为常规的这种波长变换型LED 90的结构,如图3所示,把例如发蓝色光的LED芯片91安装在一方的引线框92上,并使用金属线94与另一方的引线框93进行布线。然后,把上述LED芯片91的周围用含有荧光体96的环氧树脂95进行密封。
上述荧光体96由其粒径被设定成使平均粒径D50小于等于5μm的YAG:Ce等来代表。这样做,来自LED芯片91的蓝色光有一部分直接透过环氧树脂95,并到达观察者的眼睛,而残余的光与荧光体96接触,并在被变换成黄色光的状态下到达观察者。
因此,蓝色光与作为其补色的黄色光同时到达观察者,并作为白色光进行识别。另外,在上述环氧树脂95中,有时也添加适量(例如10wt%)的触变剂(thixotropic agent),用于在该环氧树脂95进行硬化前的这段时间内,对荧光体96因比重差而沉淀的情况进行抑制。
[专利文献1]特表平11-500584号公报
此处,如果就发明者对这种波长变换型LED的探讨结果进行说明,则确认为,如图2中用把平均粒径D50设定为约12μm时的曲线D12、设定为约13μm时的曲线D13以及设定为约24μm时的曲线D24所示,荧光体的粒径越大,波长变换效率就越高,并且当把现在采用的平均粒径至少设定成大于5μm时,例如设定成大于等于10μm时,可实现波长变换型LED的高亮度化。
然而,如果实际进行试制,则在上述说明的环氧树脂硬化前的时间内产生的荧光体的沉降极度增加,并且根据以往进行的向环氧树脂中添加触变剂的添加程度,无论如何也不能防止沉降,大部分的荧光体处于沉淀状态。因此,产生以下问题是,蓝色光和白色光的混合进行得不充分,来自波长变换型LED的光产生色彩不均匀和亮度不均匀,并且不能获得按照实验值所示的高亮度化的波长变换型LED。
发明内容
作为用于解决上述常规课题的具体手段,本发明通过提供以下波长变换型LED来解决上述课题,一种波长变换型LED,其特征在于,发光部由以下部分构成,即:激励元件,用于发出蓝色光或紫外光;荧光体,其平均粒径D50大于等于5μm且小于等于20μm,用于把来自该激励元件的发光的至少一部分变换成比激励波长长的波长;分散剂,其平均粒径D50的值大于等于荧光体的平均粒径D50的1/10;以及粘合剂基材,其含有上述荧光体和分散剂;使上述荧光体和上述分散剂合计起来的重量大于等于上述粘合剂基材的重量的20wt%小于等于60wt%;或者,一种波长变换型LED,其特征在于,发光部由以下部分构成,即:激励元件,用于发出蓝色光或紫外光;荧光体,其平均粒径D50大于等于5μm且小于等于15μm,用于把来自该激励元件的发光的至少一部分变换成比激励波长长的波长;分散剂,其平均粒径D50的值小于等于荧光体的平均粒径D50的1/100;以及粘合剂基材,其含有上述荧光体和分散剂;使上述荧光体和上述分散剂合计起来的重量小于等于上述粘合剂基材的重量的50wt%。
通过添加分散剂,可对作为环氧树脂等的粘合剂基材中的荧光体的沉降进行抑制。因此,即使当采用颗粒直径大的荧光体时,也能保持粘合剂基材中的均匀分散,并能使来自激励元件的光和来自所激励的荧光体的光的混色保持均匀性,从而可实现更高亮度的波长变换型LED。
附图说明
图1是示出根据本发明的波长变换型LED的实施方式的断面图。
图2是示出荧光体的粒径和光量的关系的图。
图3是示出常规例的断面图。
[符号说明]
1波长变换型LED;2激励元件;3粘合剂基材;4荧光体;5分散剂;6金属线;10发光部;20封装部;21壳体;21a凹部;22引出电极
具体实施方式
以下,根据如图所示的实施方式对本发明进行详细说明,图1中用符号1表示的是根据本发明的波长变换型LED,该波长变换型LED大致由参与发光的发光部10,以及用于支撑该发光部10的封装部20构成。
上述封装部20由采用树脂部件形成为具有例如大致擂钵状的凹部21a的形状的壳体21,以及设置成在上述凹部21a的底面露出一面的一对引出电极22构成,在上述凹部21a内设有发光部10。在本次说明中,尽管对被称为所谓芯片LED型的封装进行说明,然而在本发明中,如果配置成可使激励元件2在可注入含有荧光体4和分散剂5的粘合剂基材3的凹部21a中发光,则哪种封装都可以,一般可以是被称为炮弹型LED的封装,并且,即使在以大电流驱动为前提的大型芯片用封装中,本发明的主旨也不受任何影响。
上述发光部10由作为LED芯片的激励元件2、作为环氧树脂等的粘合剂基材3、荧光体4以及分散剂5构成,首先,激励元件2使用例如导电性接合剂或焊锡、Au-Sn共晶剂等以小片接合方式安装到在上述凹部21a的底面露出的引出电极22的一方上,并使用金属线6与另一方的引出电极22进行连接。作为其他激励元件安装方法,考虑了以下方法等,即:在激励元件2的单面形成两极电极,使用接合剂把元件固定,并使用金属线获得与各级对应的引出电极22的电气接触的方法;在使用导电性接合剂、焊锡、Au-Sn共晶剂、Au凸起(bump)等使与各极对应的引出电极22和形成在激励元件2的单面的电极电气接触的同时,把元件固定的方法。
如果上述激励元件2是发出含有蓝色光或紫外光的波长比蓝色光短的光的元件,则哪种都可以。一般,含有MgxZn1-xO或InxAlyGa(1-x-y)N中的任何一种的层。并且,上述粘合剂基材3可对激励元件2和金属线6、荧光体4等进行物理和化学保护,并可以透过可见光,具体地说,考虑了含有从环氧树脂、硅酮树脂、具有环氧基的聚二甲基硅氧烷衍生物、氧杂环丁烷树脂、丙烯酸树脂以及环烯树脂中选择的至少1种树脂等。
如果上述荧光体4使用由来自激励元件2的光激励并转移到长波长侧的波长进行发光,则哪种都可以,列举以下为例:例如,含有A3B5O12:M(A:Y,Gd,Lu,Tb等B:Al,Ga M:Ce3+,Tb3+,Eu3+,Cr3+,Nd3+,Er3+等),掺有稀土族元素的硫代没食子酸盐系荧光体,或者ABO3:M(A:Y,Gd,Lu,Tb B:Al,Ga M:Ce3+,Tb3+,Eu3+,Cr3+,Nd3+,Er3+)等的铝酸盐,或者(Ba,Ca,Eu)xSiyOz:Eu2+等的原硅酸盐中的至少一种组成的荧光体等。
另外,当期望上述激励元件2的发光是蓝色,并且作为上述波长变换型LED 1的发光色是白色时,如果把相对作为激励元件2的发光色的蓝色,以作为补色的黄色为发光色的荧光体4进行组合,则获得白色作为综合发光色。另外,通过组合荧光体4,也能获得白色光,该荧光体4是适当混和通过由激励元件2发出的蓝色光来发出绿色光和红色光的各荧光体而得到的。而且,当激励元件2的发光是紫外光时,通过在来自激励元件2的发光色中把R(红)、G(绿)、B(蓝)三原色的荧光体4进行组合,获得白色光。
并且,作为上述分散剂5,优选的是使来自上述激励元件2的光不产生损失,因此,无色透明或者对于光具有高反射率的部件是优选的。然后,具体地说,可以考虑氧化硅(高反射)、氧化铝(高反射)、环氧系树脂(透明)、硫酸钡(高反射)、碳酸钙(高反射)、氧化钡(高反射)、氧化钛(高反射)等。
此处,在发明者的探讨结果中,如上述说明那样,当在波长变换型LED 1中实现高亮度化时,优选的是使荧光体4的粒径在平均粒径D50中,从现状的5μm起增大。但是,如果超过20μm,则即使采取什么样的手段,也不能在粘合剂基材3的硬化工序中防止荧光体4沉淀,因而在本发明中,优选的是,荧光体4的粒径在平均粒径D50中为5~20μm的范围。
然后,在本发明中,作为用于防止上述荧光体4沉淀的手段,代替常规的添加触变剂的方法,而添加分散剂5,作为本发明的基本想法是,通过添加本来是固体的适量的分散剂5,将其掺杂在荧光体4间,并对粘合剂基材3中,即:液体中的荧光体4的移动自由度加以限制,使沉淀难以产生。
因此,发明者对用于满足上述想法的上述分散剂5的诸条件进行了探讨。结果确认到,分散剂5需要是无色透明或者反射率高,并且作为分散剂5自身不吸收来自激励元件2的光,而且在上述状态下具有分散剂5的粒径越小、光量损失就越少的倾向。
然而,同时确认到当把分散剂5的粒径设定为小于等于荧光体4的粒径的1/10时,通过添加来防止荧光体4的沉淀的效果极端减少,因而上述分散剂5的粒径的优选范围为比荧光体4的粒径小且比荧光体4的粒径的1/10大的范围(最好是大于等于1/5)。
然后,尽管是针对上述粘合剂基材3的添加量,然而由于上述荧光体4的使用量因其种类等而大不相同,因而作为针对上述粘合剂基材3的添加量,考虑到,作为与荧光体4的合计值来进行设定将更符合实际情况。这就是因为,考虑到,在荧光体4的添加量相对粘合剂基材3多的状态下,少量分散剂5的添加可防止沉淀。
这样,进行了探讨之后发现,相对于粘合剂基材3,荧光体4和分散剂5的合计添加量的必要条件是重量比大于等于20wt%且小于等于60wt%,小于等于该值(小于等于20wt%)时,沉淀防止效果表现不显著,大于等于该值(大于等于60wt%)时,把荧光体4和分散剂5的混合物添加、混合在粘合剂基材3中本身是困难的。
此处,发明者在获得以上结果的过程中发现,上述荧光体4的粒径只限在平均粒径D50中为小于等于15μm时,即使当使平均粒径D50使用小于等于其1/100(小于等于150nm)的通常被称为纳米粒子的分散剂5时,与上述同样,也可获得对荧光体4的沉淀进行抑制的作用和效果。纳米粒子分散剂的粒径的下限是1nm。纳米粒子的分散剂的沉淀抑制效果大,而另一方面具有增粘作用,所以,其配合量优选在与荧光体的合计量中,相对于含有粘合剂基材的总量控制在50wt%以内。
当采用这种纳米粒子的分散剂5时,由于纳米粒子的粒径比可见光的波长小,因而产生以下优点,针对波长变换型LED 1发出的白色光的区域,在光学上可忽视分散剂5,例如可以把因部分波长的吸收引起的发光色的着色、或者光量的损失等、通过添加分散剂5产生的问题降到最小限度。
[实施例1]
使用银膏把GaN系的激励元件2小片接合到壳体21的凹部21a内的引出电极22上,并使用金属线6进行布线。然后,在作为粘合剂基材3的环氧树脂中,分散20wt%原硅酸系的荧光体4(D50:12μm)和20wt%的SiO2的分散剂5(D50:5μm)、合计40wt%,然后将其注入上述凹部21a内。
由上述步骤获得的波长变换型LED 1的色度坐标为(0.33,0.35),在20mA、4V下进行驱动时的总光束为1.551m,没有发现亮度不均匀和色彩不均匀,并且确认为,通过添加适量的分散剂5,可以实现增大荧光体4的粒径而获得的高效率的波长变换型LED 1。
[实施例2]
使用银膏把GaN系的激励元件2芯片焊接到壳体21的凹部21a内的引出电极22上,并使用金属线6进行布线。然后,在作为粘合剂基材3的环氧树脂中,分散21wt%的原硅酸系的荧光体4(D50:12μm)和5wt%的SiO2的分散剂5(平均径:约7nm的纳米粒子)、合计26wt%,然后将其注入上述凹部21a内。
由上述步骤获得的波长变换型LED 1的色度坐标为(0.32,0.34),在20mA、4V下进行驱动时的总光束为1.641m,没有发现亮度不均匀和色彩不均匀,并且确认为,通过添加适量的纳米粒子分散剂5,可以实现通过增大荧光体4的粒径而获得的高效率的波长变换型LED 1。
另外,对于根据本发明的荧光体的粒径测定,μm级的粒子的粒径测定是使用激光衍射散射粒子分布测定法进行的,nm级的粒子的粒径测定是从SEM(扫描型电子显微镜)照片图像中读取3000个采样粒子图像的粒径,并算出其平均值。
本发明可广泛适用于白色光源的采用是必不可少的用途方面,例如,作为个人计算机、携带电话等的显示器使用的彩色液晶显示装置的背照光,或者用于对进行照明时的各颜色作出正确识别的家庭用、车辆用的照明用光源等。
Claims (6)
1.一种波长变换型LED,其特征在于,发光部由以下部分构成,即:激励元件,用于发出蓝色光或紫外光;荧光体,其平均粒径D50大于等于5μm且小于等于20μm,用于把来自该激励元件的发光的至少一部分变换成比激励波长长的波长;分散剂,其平均粒径D50的值大于等于荧光体的平均粒径D50的1/10;以及粘合剂基材,其含有上述荧光体和分散剂;使上述荧光体和上述分散剂合计起来的重量大于等于上述粘合剂基材的重量的20wt%小于等于60wt%。
2.一种波长变换型LED,其特征在于,发光部由以下部分构成,即:激励元件,用于发出蓝色光或紫外光;荧光体,其平均粒径D50大于等于5μm且小于等于15μm,用于把来自该激励元件的发光的至少一部分变换成比激励波长长的波长;分散剂,其平均粒径D50的值小于等于荧光体的平均粒径D50的1/100;以及粘合剂基材,其含有上述荧光体和分散剂;使上述荧光体和上述分散剂合计起来的重量小于等于上述粘合剂基材的重量的50wt%。
3.根据权利要求1或权利要求2所述的波长变换型LED,其特征在于,上述粘合剂基材含有从环氧树脂、硅酮树脂、具有环氧基的聚二甲基硅氧烷衍生物、氧杂环丁烷树脂、丙烯酸树脂以及环烯树脂中选择的至少1种树脂。
4.根据权利要求1~权利要求3中的任何一项所述的波长变换型LED,其特征在于,上述激励元件含有MgxZn1-xO或InxAlyGa(1-x-y)N中的任何一种的层。
5.根据权利要求1~权利要求4中的任何一项所述的波长变换型LED,其特征在于,上述分散剂含有氧化硅、氧化铝、硫酸钡、碳酸钙、氧化钡以及氧化钛中的至少一种以上。
6.根据权利要求1~权利要求5中的任何一项所述的波长变换型LED,其特征在于,上述荧光体由掺有稀土族的YAG系荧光体、或者掺有稀土族的硫代没食子酸盐系荧光体、或者含有铝酸盐、原硅酸盐中的至少一方的荧光体,或者掺有稀土族的钡-铝-镁系化合物荧光体、或者硫化物系化合物荧光体组成。
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Also Published As
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US20050035365A1 (en) | 2005-02-17 |
CN100358164C (zh) | 2007-12-26 |
JP2005064233A (ja) | 2005-03-10 |
EP1507296A1 (en) | 2005-02-16 |
US7309881B2 (en) | 2007-12-18 |
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