JP2013216800A5 - Inorganic molded body for wavelength conversion, method for producing the same, and light emitting device - Google Patents

Inorganic molded body for wavelength conversion, method for producing the same, and light emitting device Download PDF

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JP2013216800A5
JP2013216800A5 JP2012089068A JP2012089068A JP2013216800A5 JP 2013216800 A5 JP2013216800 A5 JP 2013216800A5 JP 2012089068 A JP2012089068 A JP 2012089068A JP 2012089068 A JP2012089068 A JP 2012089068A JP 2013216800 A5 JP2013216800 A5 JP 2013216800A5
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inorganic
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wavelength conversion
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Priority to KR1020130032959A priority patent/KR101549736B1/en
Priority to EP13161479.4A priority patent/EP2645433B1/en
Priority to US13/852,332 priority patent/US8994259B2/en
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本発明は、粒状の無機蛍光体を含有する無機材料からなる波長変換用無機成形体及びその製造方法、並びに波長変換用無機成形体を用いた発光装置に関する。 The present invention relates to a wavelength conversion inorganic molded body made of an inorganic material containing a granular inorganic phosphor, a method for producing the same, and a light emitting device using the wavelength conversion inorganic molded body.

本発明はかかる問題に鑑み、厚さ、形状及び用いる無機蛍光体の制約が少ない透過型の波長変換用無機成形体及びその製造方法、並びに、この波長変換用無機成形体を用いた発光装置を提供することを課題とする。 In view of such problems, the present invention provides a transmission-type wavelength conversion inorganic molded body with less restrictions on the thickness, shape, and inorganic phosphor to be used, a method for manufacturing the same, and a light-emitting device using the wavelength conversion inorganic molded body. The issue is to provide.

本発明は前記した課題を解決するために創案されたものであり、第1の発明に係る波長変換用無機成形体は、透光性の基体と、無機材料からなる波長変換部材の粒子を含有する無機粒子層と、を有し、前記無機粒子層は、凝集体と、被覆層と、空隙と、を有して構成した。 The present invention has been devised to solve the above-described problems, and the inorganic conversion body for wavelength conversion according to the first invention includes a translucent substrate and particles of a wavelength conversion member made of an inorganic material. The inorganic particle layer has an aggregate, a coating layer, and a void.

かかる構成によれば、無機粒子層に入射した第1の波長の光は、波長変換部材により吸収され、第1の波長とは異なる第2の波長の光に波長変換されて発光する。このとき、無機粒子層への入射光は、無機粒子層内に存在する空隙によって散乱され、無機粒子層内の波長変換部材に効率的に照射される。これによって、入射光は波長変換部材の粒子に効率的に吸収され、第2の波長の光に波長変換される。 According to such a configuration, light of the first wavelength incident on the inorganic particle layer is absorbed by the wavelength conversion member, it emits light when the wavelength converted into light of the second wavelength different from the first wavelength. At this time, the incident light to the inorganic particle layer is scattered by the voids existing in the inorganic particle layer, and is efficiently irradiated to the wavelength conversion member in the inorganic particle layer. Thus, the incident light is efficiently absorbed by the particles of the wavelength conversion member, is wavelength-converted into light of the second wavelength.

ここで、波長変換用無機成形体に、無機粒子層側から光が入射された場合は、入射光は無機粒子層で波長変換され、基体を透過して基体側から出射される。また、波長変換用無機成形体に、基体側から光が入射された場合は、入射光は基体を透過し無機粒子層で波長変換され、無機粒子層側から出射される。すなわち、本発明に係る波長変換用無機成形体は、透過型の波長変換用無機成形体である。 Here, when light is incident on the inorganic conversion body for wavelength conversion from the inorganic particle layer side, the incident light is wavelength- converted by the inorganic particle layer, passes through the substrate, and is emitted from the substrate side. Further, when light is incident on the inorganic conversion body for wavelength conversion from the substrate side, the incident light is transmitted through the substrate, converted in wavelength by the inorganic particle layer, and emitted from the inorganic particle layer side. That is, the wavelength conversion inorganic molded body according to the present invention is a transmission-type wavelength conversion inorganic molded body.

なお、波長変換部材は、第1の波長の光を吸収し、第1の波長とは異なる第2の波長の光を発光するものであり、例えば、窒化物蛍光体やフッ化物蛍光体などの無機蛍光体である。また、無機粒子層において、波長変換部材の粒子は、当該粒子同士又は基体と接触することで連続的に繋がった凝集体となる。そして、基の表面及び波長変換部材の粒子の表面は、無機材料からなる被覆層によって連続的に被覆される。すなわち、波長変換を行う層である無機粒子層の厚さや形状は、波長変換部材の粒子の凝集体の厚さや形状によって定められる。また、無機粒子層の内部には、被覆層で被覆された粒子、又は、被覆層で被覆された粒子及び被覆層で被覆された基体によって取り囲まれた空隙が形成される。 The wavelength conversion member absorbs light of a first wavelength, the first wavelength is intended to emit light of a second wavelength different from, for example, such as a nitride phosphor and fluoride phosphor It is an inorganic phosphor. Moreover, in the inorganic particle layer, the particles of the wavelength conversion member become aggregates continuously connected by contacting the particles or the substrate. Then, the surface of the particles on the surface and the wavelength converting member of the group member is continuously coated with a coating layer made of an inorganic material. That is, the thickness and shape of the inorganic particle layer, which is a layer that performs wavelength conversion, are determined by the thickness and shape of the aggregate of particles of the wavelength conversion member. In addition, voids surrounded by the particles coated with the coating layer, or the particles coated with the coating layer and the substrate coated with the coating layer are formed inside the inorganic particle layer.

第2の発明に係る波長変換用無機成形体は、前記無機粒子層における前記空隙は、空隙率が1〜50%であることが好ましい。
かかる構成によれば、波長変換用無機成形体は、この範囲の空隙率の空隙によって、高い含有率で波長変換部材を含有すると共に、入射光を良好に散乱して無機粒子層内の波長変換部材を照射し、効率的に入射光を波長変換する。また、この範囲の空隙率の空隙によって、波長変換無機成形体は、基体の線膨張率と無機粒子層の線膨張率との間に差がある場合でも、発熱時の熱膨張による歪を吸収してクラックの発生を防止する。
In the wavelength conversion inorganic molded body according to the second invention, the voids in the inorganic particle layer preferably have a porosity of 1 to 50%.
According to such a configuration, the wavelength- converted inorganic molded body contains the wavelength conversion member at a high content rate due to the voids in this range, and also scatters incident light well to convert the wavelength in the inorganic particle layer. The member is irradiated to efficiently convert the wavelength of incident light. In addition, due to the voids in this range, the wavelength conversion inorganic molded body absorbs strain due to thermal expansion during heat generation even when there is a difference between the linear expansion coefficient of the substrate and the linear expansion coefficient of the inorganic particle layer. To prevent the occurrence of cracks.

第3の発明に係る波長変換用無機成形体は、前記波長変換部材の粒子の平均粒径が、0.1〜100μmであり、前記被覆層の平均厚さが10nm〜50μmとすることができる。
この範囲の平均粒径の波長変換部材を用いることで、厚さの薄い波長変換用無機成形体とすることができる。また、被覆層の平均厚さをこの範囲とすることで、波長変換部材の粒子を良好に被覆することができる。
In the wavelength conversion inorganic molded body according to the third invention, the average particle diameter of the wavelength conversion member may be 0.1 to 100 μm, and the average thickness of the coating layer may be 10 nm to 50 μm. .
By using a wavelength conversion member having an average particle diameter in this range, a thin wavelength conversion inorganic molded body can be obtained. Moreover, the particle | grains of the wavelength conversion member can be coat | covered favorably by making the average thickness of a coating layer into this range.

第4の発明に係る波長変換用無機成形体は、前記無機粒子層の表面が、前記波長変換部材の粒子の粒径に起因する凹凸形状が形成されていることが好ましい。
かかる構成によれば、波長変換用無機成形体は、無機粒子層内を伝搬する光の界面での全反射を低減し、凹凸形状が形成された表面から効率的に外部に取り出すことができる。
In the inorganic conversion body for wavelength conversion according to the fourth invention, it is preferable that the surface of the inorganic particle layer has an uneven shape due to the particle size of the particles of the wavelength conversion member.
According to such a configuration, the inorganic conversion body for wavelength conversion can reduce total reflection at the interface of light propagating in the inorganic particle layer, and can be efficiently taken out from the surface on which the uneven shape is formed.

第5の発明に係る波長変換用無機成形体は、前記被覆層が、原子層堆積法により形成されたことが好ましい。
かかる構成によれば、波長変換用無機成形体は、原子層堆積法によって形成された均一で緻密な被覆層により、無機粒子層に含有される粒子が被覆されると共に、粒子間の隙間に空隙が良好に形成される。
In the wavelength conversion inorganic molded body according to the fifth invention, the coating layer is preferably formed by an atomic layer deposition method.
According to such a configuration, the inorganic conversion body for wavelength conversion is coated with the particles contained in the inorganic particle layer by the uniform and dense coating layer formed by the atomic layer deposition method, and voids are formed in the gaps between the particles. Is formed well.

第6の発明に係る波長変換用無機成形体は、前記被覆層が、Al、SiO、ZrO、HfO、TiO、ZnO、Ta、Nb、In、SnO、TiN、及びAlNから構成される群から選択される少なくとも一種の化合物を含有することが好ましい。
かかる構成によれば、波長変換用無機成形体は、好適な材料からなる被覆層で、波長変換部材の粒子を良好に被覆する。
Wavelength converting inorganic molded body according to the sixth aspect of the present invention, the coating layer, Al 2 O 3, SiO 2 , ZrO 2, HfO 2, TiO 2, ZnO, Ta 2 O 5, Nb 2 O 5, In 2 It is preferable to contain at least one compound selected from the group consisting of O 3 , SnO 2 , TiN, and AlN.
According to such a configuration, the wavelength- converting inorganic molded body satisfactorily covers the particles of the wavelength conversion member with the coating layer made of a suitable material.

第7の発明に係る波長変換用無機成形体は、前記波長変換部材が、硫化物系蛍光体、ハロゲンケイ酸塩系蛍光体、窒化物蛍光体、及び酸窒化物蛍光体から構成される群から選択される少なくとも一種の化合物を含有することができる。
かかる構成によれば、波長変換用無機成形体は、熱により失活しやすいこれらの無機蛍光体を用いて、波長変換を行うことができる。
In the wavelength conversion inorganic molded body according to the seventh invention, the wavelength conversion member is composed of a sulfide-based phosphor, a halogen silicate-based phosphor, a nitride phosphor, and an oxynitride phosphor. It can contain at least one compound selected from:
According to such a configuration, the wavelength conversion inorganic molded body can perform wavelength conversion using these inorganic phosphors that are easily deactivated by heat.

第8の発明に係る波長変換用無機成形体は、前記波長変換部材が、フッ化物蛍光体を、少なくとも含有することができる。
かかる構成によれば、波長変換用無機成形体は、水分により劣化しやすいフッ化物蛍光体を用いて、波長変換を行うことができる。
In the wavelength conversion inorganic molded body according to the eighth invention, the wavelength conversion member can contain at least a fluoride fluorescent material.
According to this configuration, the wavelength- converted inorganic molded body can perform wavelength conversion using a fluoride phosphor that is easily deteriorated by moisture.

第9の発明に係る波長変換用無機成形体は、前記波長変換部材の粒子が、当該粒子同士及び前記基体と無機結着材により結着していることが好ましい。
かかる構成によれば、波長変換用無機成形体の無機粒子層は、無機結着材により波長変換部材の粒子の凝集体が散逸することなく形成される。
In the wavelength conversion inorganic molded body according to the ninth invention, it is preferable that the particles of the wavelength conversion member are bound to each other and to the substrate and the inorganic binder.
According to such a configuration, the inorganic particle layer of the wavelength conversion inorganic molded body is formed without dissipating the aggregate of the particles of the wavelength conversion member by the inorganic binder.

第10の発明に係る波長変換用無機成形体は、前記基体が、無機材料からなることが好ましい。
かかる構成によれば、波長変換用無機成形体は、基体を無機材料で構成するため、使用時に基体が高輝度の光に照射され、また高温に晒されても、樹脂などの有機物と異なり、基体の変色などの劣化が防止される。
In the inorganic conversion body for wavelength conversion according to the tenth invention, the base is preferably made of an inorganic material.
According to such a configuration, the inorganic molded body for wavelength conversion is composed of an inorganic material, so that the substrate is irradiated with high-intensity light during use, and even when exposed to high temperatures, unlike organic substances such as resins, Deterioration such as discoloration of the substrate is prevented.

第11の発明に係る波長変換用無機成形体は、前記基体の熱伝導度が5W/m・K以上であることが好ましい。
かかる構成によれば、波長変換用無機成形体は、無機粒子層で波長変換の際に生じる熱を、熱伝導度の高い基体を介して放熱する。
In the inorganic conversion body for wavelength conversion according to the eleventh invention, it is preferable that the thermal conductivity of the substrate is 5 W / m · K or more.
According to such a configuration, the wavelength- converted inorganic molded body dissipates heat generated during wavelength conversion in the inorganic particle layer through the base having high thermal conductivity.

第12の発明に係る波長変換用無機成形体は、前記基体と前記無機粒子層との間に、透光性を有する無機材料からなる透光性層を設けることが好ましい。
かかる構成によれば、波長変換用無機成形体は、入射光又は/及び波長変換された光が透光性層と基体とを透過する透過型の波長変換用無機成形体として用いることができる。また、波長変換用無機成形体は、波長変換部材の粒子が透光性層と被覆層とによって、連続的に被覆される。
In the wavelength- converting inorganic molded body according to the twelfth invention, it is preferable to provide a light-transmitting layer made of an inorganic material having a light-transmitting property between the base and the inorganic particle layer.
According to such a configuration, the wavelength converting inorganic molded item can be used as a wavelength conversion inorganic molded of transmission-type incident light or / and wavelength converted light is transmitted through the light-transmitting layer and the substrate. In addition, in the wavelength conversion inorganic molded body, the wavelength conversion member particles are continuously coated with the translucent layer and the coating layer.

第13の発明に係る波長変換用無機成形体は、前記透光性層と前記被覆層とが同じ材料で形成されていることが好ましい。
かかる構成によれば、波長変換用無機成形体は、波長変換部材の粒子を、同じ材料からなる透光性層と被覆層とによって、連続的に被覆する。
In the wavelength conversion inorganic molded body according to the thirteenth invention, it is preferable that the translucent layer and the coating layer are formed of the same material.
According to such a configuration, the wavelength conversion inorganic molded body continuously covers the particles of the wavelength conversion member with the translucent layer and the coating layer made of the same material.

第14の発明に係る波長変換用無機成形体は、前記基体が、導電性を有する材料からなるようにすることが好ましい。
かかる構成によれば、波長変換用無機成形体は、基体に導電体層を設けることなく、基体を一方の電極とした電気沈着法又は静電塗装法を用いて、基体上に直接に無機粒子層が形成される。
In the wavelength conversion inorganic molded body according to the fourteenth aspect of the present invention, the base is preferably made of a conductive material.
According to such a configuration, the inorganic conversion body for wavelength conversion is obtained by directly forming inorganic particles on the substrate using an electrodeposition method or an electrostatic coating method using the substrate as one electrode without providing a conductor layer on the substrate. A layer is formed.

第15の発明に係る発光装置は、光源と、波長変換用無機成形体とを備えて構成される。
かかる構成によれば、発光装置は、波長変換用無機成形体によって光源が発光する第1の波長の光を吸収して、第1の波長とは異なる第2の波長の光を発光する。そして、発光装置は、この第2の波長の光を含む、波長変換用無機成形体の透過光を出力光として出力する。これによって、発光装置は、光源の光の波長波長変換した出力光を出力する。
The light emitting device according to the fifteenth aspect of the present invention includes a light source and a wavelength conversion inorganic molded body.
According to such a configuration, the light emitting device absorbs light of a first wavelength to light emission by the wavelength converting inorganic molded, emits light of a second wavelength different from the first wavelength. And a light-emitting device outputs the transmitted light of the inorganic molding for wavelength conversion containing the light of this 2nd wavelength as output light. Thus, the light emitting device outputs an output light wavelength conversion of the wavelength of the light source.

第16の発明に係る発光装置は、前記光源が発光する前記第1の波長の光の一部と、前記波長変換用無機成形体が発光する前記第2の波長の光とを混色させた光を出力するように構成することができる。
かかる構成によれば、発光装置は、光源が発光する第1の波長の光と、波長変換部材が発光する第2の波長の光とを混色させた色の光を出力する。例えば、第1の波長を青色、第2の波長を黄色として、これらを混色して白色光とすることができる。
A light-emitting device according to a sixteenth aspect of the present invention is a light obtained by mixing a part of the light having the first wavelength emitted from the light source and the light having the second wavelength emitted from the inorganic conversion body for wavelength conversion. Can be configured to output.
According to such a configuration, the light emitting device, the light source outputs a light of a first wavelength for emitting, the color of the light created by mixing light of the second wavelength is a wavelength conversion member to emit light. For example, the first wavelength can be blue, the second wavelength can be yellow, and these can be mixed into white light.

第17の発明に係る波長変換用無機成形体の製造方法は、無機粒子層形成工程と、被覆層形成工程と、を含み、この順で行われる。
かかる手順によれば、まず、無機粒子層形成工程において、基体上に、第1の波長の光を吸収し、第1の波長とは異なる第2の波長の光を発光する無機材料からなる波長変換部材の粒子を含有する凝集体を形成する。すなわち、波長変換を行う層である無機粒子層の厚さや形状は、波長変換部材の粒子の凝集体の厚さや形状によって定められる。
The method for producing an inorganic molded body for wavelength conversion according to the seventeenth invention includes an inorganic particle layer forming step and a coating layer forming step, and is performed in this order.
According to such a procedure, first, in the inorganic particle layer forming step, on the substrate, absorbs light of a first wavelength, the wavelength of inorganic material that emits light in the second wavelength different from the first wavelength Aggregates containing the particles of the conversion member are formed. That is, the thickness and shape of the inorganic particle layer, which is a layer that performs wavelength conversion, are determined by the thickness and shape of the aggregate of particles of the wavelength conversion member.

次に、被覆層形成工程において、基体の表面及び波長変換部材の粒子の表面を連続的に被覆する無機材料からなる被覆層を形成する。すなわち、前記した凝集体が、この形状を維持したまま、被覆層によって基体とともに一体化された成形体となる。 Next, in the coating layer forming step, a coating layer made of an inorganic material that continuously covers the surface of the substrate and the surfaces of the particles of the wavelength conversion member is formed. That is, the above-described aggregate becomes a molded body integrated with the substrate by the coating layer while maintaining this shape.

また、前記波長変換部材の平均粒径が、0.1〜100μmであり、前記被覆層の平均厚さが10nm〜50μmとすることができる。
かかる手順によれば、この範囲の平均粒径の波長変換部材を用いることで、厚さの薄い波長変換用無機成形体が形成される。また、被覆層の平均厚さをこの範囲とすることで、波長変換部材の粒子が良好に被覆される。
Moreover, the average particle diameter of the said wavelength conversion member is 0.1-100 micrometers, and the average thickness of the said coating layer can be 10 nm-50 micrometers.
According to this procedure, by using the wavelength conversion member having an average particle diameter in this range, a thin wavelength conversion inorganic molded body is formed. Moreover, the particle | grains of the wavelength conversion member are coat | covered favorably by making the average thickness of a coating layer into this range.

18の発明に係る波長変換用無機成形体の製造方法は、無機粒子層形成工程と、被覆層形成工程と、を含み、この順で行われる。
かかる手順によれば、まず、無機粒子層形成工程において、基体上に、第1の波長の光を吸収し、第1の波長とは異なる第2の波長の光を発光する無機材料からなる波長変換部材の粒子を含有する凝集体を形成する。すなわち、波長変換を行う層である無機粒子層の厚さや形状は、波長変換部材の粒子の凝集体の厚さや形状によって定められる。
次に、被覆層形成工程において、基体の表面及び波長変換部材の粒子の表面を連続的に被覆する無機材料からなる被覆層を形成する。すなわち、前記した凝集体が、この形状を維持したまま、被覆層によって基体とともに一体化された成形体となる。
また、前記被覆層は、Al、SiO、ZrO、HfO、TiO、ZnO、Ta、Nb、In、SnO、TiN、及びAlNから構成される群から選択される少なくとも一種の化合物を含有することが好ましい。
かかる手順によれば、被覆層形成工程において、好適な材料からなる被覆層で、波長変換部材の粒子が良好に被覆される。
The method for producing an inorganic molded body for wavelength conversion according to the eighteenth invention includes an inorganic particle layer forming step and a coating layer forming step, and is performed in this order.
According to such a procedure, first, in the inorganic particle layer forming step, a wavelength made of an inorganic material that absorbs light of the first wavelength and emits light of the second wavelength different from the first wavelength on the substrate. Aggregates containing the particles of the conversion member are formed. That is, the thickness and shape of the inorganic particle layer, which is a layer that performs wavelength conversion, are determined by the thickness and shape of the aggregate of particles of the wavelength conversion member.
Next, in the coating layer forming step, a coating layer made of an inorganic material that continuously covers the surface of the substrate and the surfaces of the particles of the wavelength conversion member is formed. That is, the above-described aggregate becomes a molded body integrated with the substrate by the coating layer while maintaining this shape.
The covering layer is made of Al 2 O 3 , SiO 2 , ZrO 2 , HfO 2 , TiO 2 , ZnO, Ta 2 O 5 , Nb 2 O 5 , In 2 O 3 , SnO 2 , TiN, and AlN. It is preferable to contain at least one compound selected from the group described above.
According to such a procedure, in the coating layer forming step, the particles of the wavelength conversion member are satisfactorily coated with the coating layer made of a suitable material.

第1の発明によれば、波長変換を行う層である無機粒子層の厚さや形状は、波長変換部材の粒子の凝集体を被覆層で被覆して、内部に空隙を設けた状態で厚さや形状を定められるため、厚さや形状を自由に定めることができる。また、このように構成することで、無機粒子層は、波長変換部材の含有率を高くすることができると共に、内部に設けられた空隙の光散乱効果により、高い波長変換効率を得ることができるため、一定の波長変換率を得るための無機粒子層の厚さを薄くすることができる。また、無機粒子層は、樹脂などの有機材料を用いることなく、無機材料で構成されるため、高輝度の光の照射や高温に晒される場合でも、経時劣化の少ない波長変換用無機成形体とすることができる。 According to the first invention, the thickness and shape of the inorganic particle layer, which is a layer that performs wavelength conversion, can be determined by covering the aggregates of the particles of the wavelength conversion member with the coating layer and providing voids therein. Since the shape can be determined, the thickness and shape can be freely determined. Moreover, by comprising in this way, an inorganic particle layer can make the content rate of a wavelength conversion member high, and can obtain high wavelength conversion efficiency by the light-scattering effect of the space | gap provided inside. Therefore, the thickness of the inorganic particle layer for obtaining a constant wavelength conversion rate can be reduced. In addition, since the inorganic particle layer is composed of an inorganic material without using an organic material such as a resin, the inorganic particle layer for wavelength conversion with little deterioration over time even when exposed to high-luminance light irradiation or high temperature can do.

第2の発明によれば、適度な空隙率の空隙を設けることで、良好な波長変換効率が得られるため、無機粒子層の厚さを薄くすることができる。また、クラックの発生を防止することができるため、製造時の歩留まりと、使用時の信頼性とを向上することができる。
第3の発明によれば、適度な平均粒径の波長変換部材と、適度な厚さの被覆層で構成することにより、無機粒子層の厚さを薄くすることができる。
第4の発明によれば、無機粒子層の表面の凹凸形状により、外部への光取り出し効率を向上することができる。
According to the second invention, by providing a void having an appropriate porosity, a good wavelength conversion efficiency can be obtained, so that the thickness of the inorganic particle layer can be reduced. Moreover, since generation | occurrence | production of a crack can be prevented, the yield at the time of manufacture and the reliability at the time of use can be improved.
According to 3rd invention, the thickness of an inorganic particle layer can be made thin by comprising with the wavelength conversion member of a moderate average particle diameter, and the coating layer of moderate thickness.
According to the fourth aspect of the invention, the light extraction efficiency to the outside can be improved by the uneven shape on the surface of the inorganic particle layer.

第5の発明によれば、原子層堆積法による緻密で均一な被覆層によって波長変換部材が被覆されるため、水分などの雰囲気により劣化しやすい蛍光体を用いても、信頼性の高い波長変換用無機成形体とすることができる。また、原子層堆積法により、比較的低温で被覆層が形成されるため、熱により劣化しやすい蛍光体を用いた波長変換用無機成形体を形成することができる。更に、無機粒子層の粒子間の隙間に良好に空隙が形成されるため、波長変換効率を向上することができる。 According to the fifth aspect of the invention, since the wavelength conversion member is covered with a dense and uniform coating layer formed by atomic layer deposition, highly reliable wavelength conversion is possible even when using a phosphor that is easily deteriorated by an atmosphere such as moisture. It can be used as an inorganic molded product. Further, since the coating layer is formed at a relatively low temperature by the atomic layer deposition method, an inorganic molded body for wavelength conversion using a phosphor that is easily deteriorated by heat can be formed. Furthermore, since the voids are favorably formed in the gaps between the particles of the inorganic particle layer, the wavelength conversion efficiency can be improved.

第6の発明によれば、好適な材料を用いた被覆層により波長変換部材が雰囲気から保護されるため、信頼性が向上する。
第7の発明又は第8の発明によれば、波長変換部材として、熱や雰囲気により失活しやすい蛍光体を用いることができるため、様々な色、例えば、赤色に波長変換する波長変換用無機成形体を構成することができる。
第9の発明によれば、無機結着材により波長変換部材の粒子の凝集体が散逸することなく成形体が形成されるため、無機粒子層の形状が安定する。
According to the sixth aspect of the invention, the wavelength conversion member is protected from the atmosphere by the coating layer using a suitable material, so that the reliability is improved.
According to the seventh invention or the eighth invention, as the wavelength conversion member, it is possible to use inactivated easily phosphor by heat or atmosphere, a variety of colors, for example, inorganic wavelength converting wavelength conversion to red A molded object can be comprised.
According to the ninth aspect, since the formed body is formed by the inorganic binder without the aggregates of the particles of the wavelength conversion member being dissipated, the shape of the inorganic particle layer is stabilized.

第10の発明によれば、無機材料からなる基体は、高輝度の光や高温に晒されても劣化しにくいため、波長変換用無機成形体の信頼性を向上することができる。
第11の発明によれば、高熱伝導率の基体を介して無機粒子層で生じる熱を効率的に放熱することができるため、波長変換用無機成形体の信頼性を向上することができる。
According to the tenth invention, since the substrate made of an inorganic material is not easily deteriorated even when exposed to high-luminance light or high temperature, the reliability of the wavelength conversion inorganic molded body can be improved.
According to the eleventh aspect, since heat generated in the inorganic particle layer can be efficiently radiated through the substrate having high thermal conductivity, the reliability of the inorganic conversion body for wavelength conversion can be improved.

第12の発明によれば、波長変換用無機成形体は、波長変換部材の粒子が無機材料からなる透光性層と無機材料からなる被覆層とによって、連続的に被覆されるため、波長変換部材を、より良好に水分などの雰囲気から保護することができる。
第13の発明によれば、波長変換用無機成形体は、波長変換部材の粒子が、同じ材料からなる透光性層と被覆層とによって、連続的に被覆されるため、波長変換部材を、更に良好に水分などの雰囲気から保護することができる。
第14の発明によれば、波長変換用無機成形体は、基体上に直接に無機粒子層を設けることができるため、基体以外の余分な層により光が吸収されることがない。
According to the twelfth aspect of the invention, the wavelength conversion inorganic molded body is continuously coated with the light- transmitting layer made of an inorganic material and the coating layer made of an inorganic material, so that the wavelength conversion member particles are wavelength- converted. The member can be better protected from an atmosphere such as moisture.
According to the thirteenth invention, the wavelength converting inorganic moldings, the particles of the wavelength conversion member by the light-transmitting layer and the coating layer made of the same material, because they are continuously coated, the wavelength conversion member, Further, it can be well protected from an atmosphere such as moisture.
According to the fourteenth aspect of the invention, the wavelength- converting inorganic molded body can be provided with the inorganic particle layer directly on the base, so that light is not absorbed by an extra layer other than the base.

第15の発明によれば、発光装置は、無機材料からなる波長変換用無機成形体を用いて波長変換を行うため、信頼性の高い高輝度の発光装置とすることができる。
第16の発明によれば、発光装置は、入射光と波長変換用無機成形体が発光した光とを混色して出力するため、発光装置として出力する出力光の色の選択肢を増やすことができる。
According to the fifteenth invention, the light emitting device, for performing wavelength conversion using the wavelength converting inorganic molded article comprising the inorganic material may be a light emitting device of high reliability high luminance.
According to the sixteenth invention, the light emitting device mixes and outputs the incident light and the light emitted from the wavelength conversion inorganic molded body, so that the choice of the color of the output light output as the light emitting device can be increased. .

第17の発明又は第18の発明によれば、波長変換を行う層である無機粒子層の厚さや形状は、波長変換部材の粒子の凝集体の厚さや形状として定められるため、厚さや形状を自由に定めることができる。また、波長変換部材の粒子の凝集体を被覆層で被覆することで成形体とするため、無機粒子層における波長変換部材の含有率を高くすることができると共に、内部に設けられた空隙の光散乱効果により、高い波長変換効率を得ることができる。このため、一定の波長変換率を得るための無機粒子層の厚さを薄くすることができる。また、無機粒子層は、樹脂などの有機材料を用いることなく、無機材料で形成されるため、高輝度の光の照射や高温に晒される場合でも、経時劣化の少ない透過型の波長変換用無機成形体を製造することができる。 According to the seventeenth aspect or the eighteenth aspect, the thickness and shape of the inorganic particle layer, which is the layer that performs wavelength conversion, are determined as the thickness and shape of the aggregate of the particles of the wavelength conversion member. It can be determined freely. Further, since the aggregate of the wavelength conversion member particles is coated with a coating layer to form a molded body, the content of the wavelength conversion member in the inorganic particle layer can be increased, and the light in the voids provided inside High wavelength conversion efficiency can be obtained by the scattering effect. For this reason, the thickness of the inorganic particle layer for obtaining a constant wavelength conversion rate can be reduced. In addition, since the inorganic particle layer is formed of an inorganic material without using an organic material such as a resin, it is a transmission-type wavelength conversion inorganic material that has little deterioration over time even when exposed to high-intensity light irradiation or high temperatures. A molded body can be produced.

また、17の発明によれば、適度な平均粒径の波長変換部材を用い、適度な厚さの被覆層を形成することにより、無機粒子層の厚さを薄くすることができる。
18の発明によれば、好適な材料を用いた被覆層により波長変換部材が雰囲気から保護されるため、信頼性の高い波長変換用無機成形体を製造することができる。
Further, according to the seventeenth invention, using a wavelength converting member of a moderate average particle size, by forming a coating layer of moderate thickness, it is possible to reduce the thickness of the inorganic particle layer.
According to the eighteenth aspect , since the wavelength conversion member is protected from the atmosphere by the coating layer using a suitable material, it is possible to manufacture a highly reliable inorganic conversion body for wavelength conversion.

<第1実施形態>
[無機成形体の構成]
本発明の第1実施形態に係る無機成形体の構造を、図1を参照して説明する。
図1(a)に示すように、第1実施形態に係る無機成形体1は、透光性の基板2の上面に透光性層5を有し、透光性層5を介して基板2の上面に蛍光体層(無機粒子層)3が設けられている。また、蛍光体層3は、粒状の無機蛍光体(波長変換部材)31と、無機蛍光体31を被覆する被覆層32とから形成されている。更に詳細には、図1(b)に示すように、蛍光体層3の内部には、空隙33が形成されている。
<First Embodiment>
[Configuration of inorganic molded body]
The structure of the inorganic molded body according to the first embodiment of the present invention will be described with reference to FIG.
As shown in FIG. 1A, the inorganic molded body 1 according to the first embodiment has a translucent layer 5 on the upper surface of a translucent substrate 2, and the substrate 2 is interposed via the translucent layer 5. A phosphor layer (inorganic particle layer) 3 is provided on the upper surface of the substrate. The phosphor layer 3 is formed of a granular inorganic phosphor ( wavelength conversion member) 31 and a coating layer 32 that covers the inorganic phosphor 31. More specifically, as shown in FIG. 1B, a gap 33 is formed inside the phosphor layer 3.

(無機蛍光体(波長変換部材))
無機蛍光体31は、蛍光体層3に入射した光を吸収し、入射光の色とは異なる色の光を発光する無機材料からなる蛍光体である。
無機蛍光体31として使用される蛍光体材料は、励起光である入射光を吸収して、異なる色(波長)の光に色変換(波長変換)するものであればよい。特に、無機蛍光体31が、紫外光ないし青色光を吸収して、青色光ないし赤色光を放出する材料であることが好ましい。
(Inorganic phosphor ( wavelength conversion member))
The inorganic phosphor 31 is a phosphor made of an inorganic material that absorbs light incident on the phosphor layer 3 and emits light of a color different from the color of the incident light.
The phosphor material used as the inorganic phosphor 31 may be any material that absorbs incident light that is excitation light and performs color conversion (wavelength conversion) to light of a different color (wavelength). In particular, the inorganic phosphor 31 is preferably a material that absorbs ultraviolet light or blue light and emits blue light or red light.

(色変換用成形部材(波長変換用無機成形体))
色変換用成形部材12は、サブマウント15の凹部15aの開口部を塞ぐように設けられ、下面から入射される光源11からの入射光L1を、入射光L1とは異なる色の光に色変換した透過光L2を上面から出射する透過型の色変換用成形部材である。本実施形態では、図1に示した第1実施形態に係る無機成形体1を用いるものである。
(Color conversion molding member (inorganic molding for wavelength conversion))
The color conversion molding member 12 is provided so as to close the opening of the recess 15a of the submount 15, and converts the incident light L1 from the light source 11 incident from the lower surface into light of a color different from the incident light L1. This is a transmissive color conversion molding member that emits the transmitted light L2 from the upper surface. In the present embodiment, the inorganic molded body 1 according to the first embodiment shown in FIG. 1 is used.

(色変換用成形部材(波長変換用無機成形体))
色変換用成形部材12A及び色変換用成形部材12Aは、光源11からの入射光L1を、入射光L1とは異なる色の透過光L2として出射する、透過型の色変換用無機成形体である。本実施形態では、色変換用成形部材12A及び色変換用成形部材12Aには、第1実施形態に係る無機成形体1が適用される。また、色変換用成形部材12A及び色変換用成形部材12Aは、青色光を、それぞれ赤色光及び緑色光に色変換する無機蛍光体31を含有する蛍光体層3を有している。
(Color conversion molding member (inorganic molding for wavelength conversion))
The color conversion molding member 12A R and the color conversion molding member 12A G emit the incident light L1 from the light source 11 as transmitted light L2 having a color different from that of the incident light L1. It is. In the present embodiment, the inorganic molded body 1 according to the first embodiment is applied to the color conversion molding member 12A R and the color conversion molding member 12A G. Further, the color conversion molding member 12A R and the color conversion molding member 12A G have a phosphor layer 3 containing an inorganic phosphor 31 that converts blue light into red light and green light, respectively.

1、1A、1A、1A、1B 無機成形体(波長変換用無機成形体)
2、2B 基板(基体)
3 蛍光体層(無機粒子層)
31 無機蛍光体(波長変換部材)
32 被覆層
33 空隙
34 粒子層(凝集体)
5 透光性層
6 導電体層
10、10A 発光装置
11 光源
12、12A、12A 色変換用成形部材(波長変換用無機成形体)
13 カラーホイール
13a 回転軸
15 サブマウント
15a 凹部
16 透光部材
20 マスキング部材
1, 1A 1 , 1A 2 , 1A 3 , 1B inorganic molded body (inorganic molded body for wavelength conversion)
2, 2B substrate (base)
3 Phosphor layer (inorganic particle layer)
31 Inorganic phosphor ( wavelength conversion member)
32 Coating layer 33 Void 34 Particle layer (aggregate)
DESCRIPTION OF SYMBOLS 5 Translucent layer 6 Conductor layer 10, 10A Light-emitting device 11 Light source 12, 12A R , 12A G color conversion molding member (inorganic molding for wavelength conversion)
13 Color wheel 13a Rotating shaft 15 Submount 15a Concave portion 16 B Translucent member 20 Masking member

Claims (18)

透光性の基体と、
前記基体上に設けられた、第1の波長の光を吸収し、前記第1の波長とは異なる第2の波長の光を発光する無機材料からなる波長変換部材の粒子を含有する無機粒子層と、を有し、
前記無機粒子層は、
前記粒子が、当該粒子同士又は前記基体と接触することで連続的に繋がった凝集体と、
前記基体の表面及び前記粒子の表面を連続的に被覆する無機材料からなる被覆層と、
前記被覆層で被覆された前記粒子、又は、前記被覆層で被覆された前記粒子及び前記被覆層で被覆された前記基体によって取り囲まれた空隙と、
を有することを特徴とする波長変換用無機成形体。
A translucent substrate;
Provided on the substrate, the inorganic particle layer first absorbs light of a wavelength, containing particles of different second wavelength converting member made of an inorganic material that emits light in the wavelength from the first wavelength And having
The inorganic particle layer is
Aggregates in which the particles are continuously connected by contacting the particles or the substrate;
A coating layer made of an inorganic material that continuously covers the surface of the substrate and the surface of the particles;
A void surrounded by the particles coated with the coating layer, or the particles coated with the coating layer and the substrate coated with the coating layer ;
An inorganic molded article for wavelength conversion, characterized by comprising:
前記無機粒子層における前記空隙は、空隙率が1〜50%であることを特徴とする請求項1に記載の波長変換用無機成形体。 2. The wavelength- converted inorganic molded article according to claim 1, wherein the voids in the inorganic particle layer have a porosity of 1 to 50%. 前記波長変換部材の粒子の平均粒径は、0.1〜100μmであり、
前記被覆層の平均厚さが10nm〜50μmであることを特徴とする請求項1又は請求項2に記載の波長変換用無機成形体。
The average particle diameter of the wavelength conversion member particles is 0.1 to 100 μm,
The inorganic molding for wavelength conversion according to claim 1 or 2, wherein an average thickness of the coating layer is 10 nm to 50 µm.
前記無機粒子層の表面は、前記波長変換部材の粒子の粒径に起因する凹凸形状が形成されていることを特徴とする請求項1乃至請求項3の何れか一項に記載の波長変換用無機成形体。 Surface of the inorganic particle layer, the wavelength converting according to any one of claims 1 to 3, characterized in that irregularities caused by the size of the particles of the wavelength conversion member is formed Inorganic molded body. 前記被覆層は、原子層堆積法により形成されたことを特徴とする請求項1乃至請求項4の何れか一項に記載の波長変換用無機成形体。 The wavelength- converting inorganic molded body according to any one of claims 1 to 4, wherein the coating layer is formed by an atomic layer deposition method. 前記被覆層は、Al、SiO、ZrO、HfO、TiO、ZnO、Ta、Nb、In、SnO、TiN、及びAlNから構成される群から選択される少なくとも一種の化合物を含有することを特徴とする請求項1乃至請求項5の何れか一項に記載の波長変換用無機成形体。 The coating layer is made of Al 2 O 3 , SiO 2 , ZrO 2 , HfO 2 , TiO 2 , ZnO, Ta 2 O 5 , Nb 2 O 5 , In 2 O 3 , SnO 2 , TiN, and AlN. The inorganic molded body for wavelength conversion according to any one of claims 1 to 5, comprising at least one compound selected from the group. 前記波長変換部材は、硫化物系蛍光体、ハロゲンケイ酸塩系蛍光体、窒化物蛍光体、及び酸窒化物蛍光体から構成される群から選択される少なくとも一種の化合物を含有することを特徴とする請求項1乃至請求項6の何れか一項に記載の波長変換用無機成形体。 The wavelength conversion member contains at least one compound selected from the group consisting of sulfide phosphors, halogen silicate phosphors, nitride phosphors, and oxynitride phosphors. The inorganic molded object for wavelength conversion as described in any one of Claim 1 thru | or 6. 前記波長変換部材は、フッ化物蛍光体を、少なくとも含有することを特徴とする請求項1乃至請求項7の何れか一項に記載の波長変換用無機成形体。 The wavelength- converting inorganic substance for wavelength conversion according to any one of claims 1 to 7, wherein the wavelength conversion member contains at least a fluoride phosphor. 前記波長変換部材の粒子は、当該粒子同士及び前記基体と無機結着材により結着していることを特徴とする請求項1乃至請求項8の何れか一項に記載の波長変換用無機成形体。 Particles of the wavelength conversion member, the wavelength converting inorganic molding according to any one of claims 1 to 8, characterized in that it is bound by the particles to each other and the substrate and the inorganic binder body. 前記基体は、無機材料からなることを特徴とする請求項1乃至請求項9の何れか一項に記載の波長変換用無機成形体。 The inorganic substrate for wavelength conversion according to any one of claims 1 to 9, wherein the substrate is made of an inorganic material. 前記基体の熱伝導度が5W/m・K以上であることを特徴とする請求項1乃至請求項10の何れか一項に記載の波長変換用無機成形体。 The inorganic molded body for wavelength conversion according to any one of claims 1 to 10, wherein the substrate has a thermal conductivity of 5 W / m · K or more. 前記基体と前記無機粒子層との間に、透光性を有する無機材料からなる透光性層を設けたことを特徴とする請求項1乃至請求項11の何れか一項に記載の波長変換用無機成形体。 The wavelength conversion according to any one of claims 1 to 11, wherein a translucent layer made of a translucent inorganic material is provided between the base and the inorganic particle layer. Inorganic molded body. 前記透光性層と前記被覆層とが同じ材料で形成されていることを特徴とする請求項12に記載の波長変換用無機成形体。 The inorganic molded body for wavelength conversion according to claim 12, wherein the translucent layer and the coating layer are formed of the same material. 前記基体が、導電性を有する材料からなることを特徴とする請求項1乃至請求項11の何れか一項に記載の波長変換用無機成形体。 The inorganic base for wavelength conversion according to any one of claims 1 to 11, wherein the base is made of a conductive material. 光源と、
前記光源が発光する第1の波長の光を吸収して、前記第1の波長とは異なる第2の波長の光を発光する請求項1乃至請求項14の何れか一項に記載の波長変換用無機成形体とを備え、
前記第2の波長の光を含む光を出力することを特徴とする発光装置。
A light source;
The wavelength conversion according to claim 1, wherein the light source emits light having a second wavelength different from the first wavelength by absorbing light having a first wavelength emitted from the light source. An inorganic molded body for
A light-emitting device that outputs light including light of the second wavelength .
前記光源が発光する前記第1の波長の光の一部と、前記波長変換用無機成形体が発光する前記第2の波長の光とを混色させた光を出力することを特徴とする請求項15に記載の発光装置。 Claims, characterized in that said light source outputs a portion of the light of the first wavelength for emitting the light created by mixing light of the second wavelength the wavelength converting inorganic molded emits light 15. The light emitting device according to 15. 透光性の基体上に、第1の波長の光を吸収し、前記第1の波長とは異なる第2の波長の光を発光する無機材料からなる波長変換部材の粒子を含有する凝集体を形成する無機粒子層形成工程と、
前記基体の表面及び前記粒子の表面を連続的に被覆する無機材料からなる被覆層を形成する被覆層形成工程と、を含み、
前記波長変換部材の平均粒径は、0.1〜100μmであり、
前記被覆層の平均厚さが10nm〜50μmであることを特徴とする波長変換用無機成形体の製造方法。
An aggregate containing particles of a wavelength conversion member made of an inorganic material that absorbs light of a first wavelength and emits light of a second wavelength different from the first wavelength on a light-transmitting substrate. An inorganic particle layer forming step to be formed;
A coating layer forming step of forming a coating layer made of an inorganic material that continuously covers the surface of the substrate and the surface of the particles,
The average particle diameter of the wavelength conversion member is 0.1 to 100 μm,
Method for manufacturing a wavelength conversion inorganic molded you wherein the average thickness of the coating layer is 10Nm~50myuemu.
透光性の基体上に、第1の波長の光を吸収し、前記第1の波長とは異なる第2の波長の光を発光する無機材料からなる波長変換部材の粒子を含有する凝集体を形成する無機粒子層形成工程と、
前記基体の表面及び前記粒子の表面を連続的に被覆する無機材料からなる被覆層を形成する被覆層形成工程と、を含み、
前記被覆層は、Al、SiO、ZrO、HfO、TiO、ZnO、Ta、Nb、In、SnO、TiN、及びAlNから構成される群から選択される少なくとも一種の化合物を含有することを特徴とする波長変換用無機成形体の製造方法。
An aggregate containing particles of a wavelength conversion member made of an inorganic material that absorbs light of a first wavelength and emits light of a second wavelength different from the first wavelength on a light-transmitting substrate. An inorganic particle layer forming step to be formed;
A coating layer forming step of forming a coating layer made of an inorganic material that continuously covers the surface of the substrate and the surface of the particles,
The coating layer is made of Al 2 O 3 , SiO 2 , ZrO 2 , HfO 2 , TiO 2 , ZnO, Ta 2 O 5 , Nb 2 O 5 , In 2 O 3 , SnO 2 , TiN, and AlN. method for manufacturing a wavelength conversion inorganic molded you characterized in that it contains at least one compound selected from the group.
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KR1020130032959A KR101549736B1 (en) 2012-03-28 2013-03-27 Inorganic shaped body for converting wavelength and method for manufacturing the same, and light emitting device
EP13161479.4A EP2645433B1 (en) 2012-03-28 2013-03-27 Wave-length conversion inorganic member, method for manufacturing the same, and light emitting device
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JP6428194B2 (en) * 2014-11-21 2018-11-28 日亜化学工業株式会社 Wavelength converting member, method for manufacturing the same, and light emitting device
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