JP5016187B2 - Nitride phosphor, method for producing nitride phosphor, light source and LED using the nitride phosphor - Google Patents
Nitride phosphor, method for producing nitride phosphor, light source and LED using the nitride phosphor Download PDFInfo
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- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 title claims description 131
- 150000004767 nitrides Chemical class 0.000 title claims description 65
- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 238000010304 firing Methods 0.000 claims description 33
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 27
- 229910052799 carbon Inorganic materials 0.000 claims description 27
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 23
- 239000001301 oxygen Substances 0.000 claims description 23
- 229910052760 oxygen Inorganic materials 0.000 claims description 23
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 18
- 239000000843 powder Substances 0.000 claims description 16
- 230000005284 excitation Effects 0.000 claims description 14
- 229910052582 BN Inorganic materials 0.000 claims description 12
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 12
- 239000002245 particle Substances 0.000 claims description 12
- 239000012298 atmosphere Substances 0.000 claims description 9
- 229910052757 nitrogen Inorganic materials 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 8
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- 239000012190 activator Substances 0.000 claims description 6
- 229910052791 calcium Inorganic materials 0.000 claims description 6
- 229910052710 silicon Inorganic materials 0.000 claims description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- 229910052788 barium Inorganic materials 0.000 claims description 5
- 229910052749 magnesium Inorganic materials 0.000 claims description 5
- 239000010703 silicon Substances 0.000 claims description 5
- 229910052712 strontium Inorganic materials 0.000 claims description 5
- 229910052725 zinc Inorganic materials 0.000 claims description 4
- 238000011049 filling Methods 0.000 claims description 2
- 239000012535 impurity Substances 0.000 description 31
- 239000002994 raw material Substances 0.000 description 13
- 230000007423 decrease Effects 0.000 description 11
- 238000000034 method Methods 0.000 description 9
- 238000002156 mixing Methods 0.000 description 8
- 239000000203 mixture Substances 0.000 description 7
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 5
- 238000005286 illumination Methods 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 239000004570 mortar (masonry) Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 229910007991 Si-N Inorganic materials 0.000 description 3
- 229910006294 Si—N Inorganic materials 0.000 description 3
- 229910052772 Samarium Inorganic materials 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000007580 dry-mixing Methods 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 229910052753 mercury Inorganic materials 0.000 description 2
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 229910005191 Ga 2 O 3 Inorganic materials 0.000 description 1
- 229910005793 GeO 2 Inorganic materials 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 229910003668 SrAl Inorganic materials 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 229910052790 beryllium Inorganic materials 0.000 description 1
- 229910052793 cadmium Inorganic materials 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- -1 for example Chemical compound 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 229910052761 rare earth metal Inorganic materials 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910052723 transition metal Inorganic materials 0.000 description 1
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Description
本発明は、ＣＲＴ、ＰＤＰ、ＦＥＤ、ＥＬなどのディスプレイ装置や、蛍光表示管、蛍光ランプなどの照明装置等に使用される蛍光体に関するものであり、特に、紫外〜緑色の光により励起され、可視光または白色光を発光させるための窒化物蛍光体、窒化物蛍光体の製造方法、並びに上記窒化物蛍光体を用いた光源及びＬＥＤに関する。 The present invention relates to a phosphor used in display devices such as CRT, PDP, FED, EL, etc., and illumination devices such as fluorescent display tubes, fluorescent lamps, etc., and is excited by ultraviolet to green light, The present invention relates to a nitride phosphor for emitting visible light or white light, a method for producing the nitride phosphor, and a light source and an LED using the nitride phosphor.
現在、照明装置として用いられている放電式蛍光灯や白熱電球などは、水銀などの有害物質が含まれ、且つ寿命が短いといった諸問題を抱えている。ところが近年になって青色や紫外に発光するＬＥＤが次々と開発され、そのＬＥＤから発生する紫外〜緑色の光と、紫外〜緑色の波長域に励起帯を持つ蛍光体との組み合わせにより、白色の光を発する次世代の照明装置を得ようとする研究、開発が盛んに行われている。この照明装置は、熱の発生量が少なく、また、半導体素子(ＬＥＤ)と蛍光体から構成されているため白熱電球のように切れる心配がなく長寿命であり、更に、水銀などの有害物質が不要であるなどの多くの利点があり、理想的な照明装置である。 Currently, discharge fluorescent lamps and incandescent lamps used as lighting devices have various problems such as containing harmful substances such as mercury and short life. However, in recent years, LEDs that emit blue and ultraviolet light have been developed one after another, and the combination of ultraviolet to green light generated from the LED and a phosphor having an excitation band in the ultraviolet to green wavelength range has allowed white light to be emitted. Research and development to obtain a next-generation lighting device that emits light is actively conducted. This lighting device has a small amount of heat generation, and is composed of a semiconductor element (LED) and a phosphor, so it has a long life without fear of breaking like an incandescent light bulb. There are many advantages such as unnecessary, and it is an ideal lighting device.
ここで、上述のＬＥＤと蛍光体とを組み合せて白色光を得るには、一般的に2つの方式が考えられる。一つは、青色を発光するＬＥＤと、当該青色発光を受けて励起され黄色を発光する蛍光体とを組み合せ、これら補色関係にある青色発光と黄色発光との組み合せにより白色発光を得るものである。 Here, in order to obtain white light by combining the above-described LED and phosphor, generally two methods are conceivable. One is a combination of an LED that emits blue light and a phosphor that receives the blue light emission and is excited to emit yellow light, and obtains white light emission by a combination of blue light emission and yellow light emission that are complementary to each other. .
他の一つは、近紫外や紫外を発光するＬＥＤと、当該近紫外や紫外の発光により励起されて赤色（Ｒ）を発光する蛍光体、緑色（Ｇ）を発光する蛍光体、青色（Ｂ）を発光する蛍光体、他の色を発光する蛍光体とを組み合せ、当該ＲＧＢ等の光の混合により白色発光を得るものである。このＲＧＢ等の光により白色発光を得る方法は、ＲＧＢ等の光を発光する蛍光体の組み合せや混合比などにより、白色光以外にも任意の発光色を得ることが可能であり、照明装置としての応用範囲が広い。 The other one is an LED that emits near ultraviolet or ultraviolet light, a phosphor that emits red (R) when excited by the near ultraviolet or ultraviolet light emission, a phosphor that emits green (G), and blue (B ) And a phosphor emitting another color, and white light emission is obtained by mixing light such as RGB. This method of obtaining white light emission by light such as RGB can obtain any light emission color other than white light depending on the combination or mixing ratio of phosphors that emit light such as RGB. Wide application range.
この用途に使用される蛍光体としては、赤色蛍光体であれば、例えば、Ｙ２Ｏ２Ｓ：Ｅｕ、Ｌａ２Ｏ２Ｓ：Ｅｕ、３．５ＭｇＯ・０．５ＭｇＦ２・ＧｅＯ２：Ｍｎ、（Ｌａ、Ｍｎ、Ｓｍ）２Ｏ２Ｓ・Ｇａ２Ｏ３があり、緑色蛍光体であれば、例えば、ＺｎＳ：Ｃｕ，Ａｌ、ＳｒＡｌ２Ｏ４：Ｅｕ、ＢＡＭ：Ｅｕ，Ｍｎがあり、黄色蛍光体であれば、例えば、ＹＡＧ：Ｃｅがあり、青色蛍光体であれば、例えば、ＢＡＭ：Ｅｕ、Ｓｒ５（ＰＯ４）３Ｃｌ：Ｅｕ、ＺｎＳ：Ａｇ、（Ｓｒ、Ｃａ、Ｂａ、Ｍｇ）１０（ＰＯ４）６Ｃｌ：Ｅｕがある。そして、これらのＲＧＢ等を発光する蛍光体を、近紫外や紫外を発光するＬＥＤなどの発光部(発光素子)と組み合せることにより、白色または所望の単色を発光するＬＥＤを始めとした光源や、当該光源を備えた照明装置を得ることが可能となる。 As a phosphor used for this application, if it is a red phosphor, for example, Y 2 O 2 S: Eu, La 2 O 2 S: Eu, 3.5MgO · 0.5MgF 2 · GeO 2 : Mn, If there is (La, Mn, Sm) 2 O 2 S · Ga 2 O 3 and it is a green phosphor, for example, there are ZnS: Cu, Al, SrAl 2 O 4 : Eu, BAM: Eu, Mn, yellow For example, YAG: Ce may be used as the phosphor, and BAM: Eu, Sr 5 (PO 4 ) 3 Cl: Eu, ZnS: Ag, (Sr, Ca, Ba, Mg) may be used as the blue phosphor. ) 10 (PO 4 ) 6 Cl: Eu. And, by combining these phosphors that emit RGB and the like with light emitting parts (light emitting elements) such as LEDs that emit near ultraviolet or ultraviolet light, light sources such as LEDs that emit white light or a desired single color, It is possible to obtain an illumination device including the light source.
しかし、青色ＬＥＤと黄色蛍光体（ＹＡＧ：Ｃｅ）の組み合せにより白色を得る照明にあっては、可視光領域の長波長側の発光が不足してしまうため、若干青みを帯びた白色の発光となってしまい、電球のようなやや赤みを帯びた白色発光を得ることができない。 However, in the illumination that obtains white color by combining the blue LED and the yellow phosphor (YAG: Ce), the light emission on the long wavelength side in the visible light region is insufficient. As a result, it is not possible to obtain white light emission that is slightly reddish like a light bulb.
また、近紫外・紫外ＬＥＤとＲＧＢ等を発光する蛍光体との組み合せにより白色を得る照明では、3色の蛍光体のうち赤色蛍光体が他の蛍光体に比べ長波長側の励起効率が悪く、発光効率が低下するため、赤色蛍光体の混合割合を多くせざるを得ず、輝度を向上させる蛍光体が不足して高輝度の白色が得られない。 In addition, in illumination that obtains white color by combining near-ultraviolet / ultraviolet LEDs and phosphors that emit RGB, etc., the red phosphor of the three color phosphors has lower excitation efficiency on the longer wavelength side than the other phosphors. Since the luminous efficiency is reduced, the mixing ratio of the red phosphors must be increased, and the phosphors for improving the luminance are insufficient, and a high luminance white color cannot be obtained.
そのため最近では、長波長側に良好な励起を持ち、半値幅の広い発光ピークが得られるオキシ窒化物ガラス蛍光体（例えば、特許文献１参照）や、サイアロンを母体とする蛍光体（例えば、特許文献２、３、４参照）、シリコンナイトライド系などの窒素を含有した蛍光体（例えば、特許文献５、６参照）が提案されている。これらの窒素を含有した蛍光体は、酸化物系蛍光体などに比べて共有結合の割合が多くなるため、波長４００ｎｍ以上の光においても良好な励起帯を有し、白色の光を発する照明装置用の蛍光体として注目されている。
Therefore, recently, an oxynitride glass phosphor that has good excitation on the long wavelength side and a broad emission half-width emission peak (see, for example, Patent Document 1), and a phosphor based on sialon (for example, a patent)
上述の紫外〜緑色に発光する発光素子と、当該発光素子から発生する紫外〜緑色の波長域に対して励起帯を持つ蛍光体との組合せにより可視光、白色光を発するＬＥＤを始めとした光源においては、可視光または白色光の発光特性向上のために、発光素子及び蛍光体の発光効率の向上や安定性が求められる。ところが従来の技術に係る蛍光体においては、発光効率が製造バッチ毎に安定しているとは限らず、発光効率にバラツキがみられることがあった。ここで、本発明者らは当該バラツキの原因を究明し、その対策を打つことが出きれば、当該蛍光体の発光効率をより高めることができるのではないかと考えた。
そこで本発明者らは、様々な蛍光体の試料を調製し当該バラツキの原因を追求したところ、当該蛍光体中に不純物として含まれる炭素および／または酸素が原因であることに想到した。
ここで本発明者らは、当該不純物として含まれる炭素および／または酸素の由来について、さらに研究をおこなった。その結果、当該元素は、当初予想された雰囲気等に由来するものだけでなく、窒化物蛍光体製造時の焼結工程において、焼成容器内から窒化物蛍光体中に拡散して不純物となるものもあることに想到した。
Light sources such as LEDs that emit visible light and white light by combining the light emitting element that emits ultraviolet to green light and a phosphor having an excitation band in the ultraviolet to green wavelength range generated from the light emitting element. However, in order to improve the light emission characteristics of visible light or white light, improvement in light emission efficiency and stability of the light emitting element and the phosphor are required. However, in the phosphor according to the conventional technique, the light emission efficiency is not always stable for each production batch, and the light emission efficiency sometimes varies. Here, the present inventors have investigated the cause of the variation, and thought that the luminous efficiency of the phosphor could be further improved if the countermeasure can be taken.
Therefore, the present inventors prepared various phosphor samples and pursued the cause of the variation, and came up with the cause of carbon and / or oxygen contained as impurities in the phosphor.
Here, the present inventors have further studied the origin of carbon and / or oxygen contained as the impurities. As a result, the element is not only derived from the originally anticipated atmosphere, but also diffuses into the nitride phosphor from the firing vessel and becomes an impurity in the sintering process when producing the nitride phosphor. I came up with that.
本発明の目的は、上述の事情を考慮してなされたものであり、窒化物蛍光体中に当該不純物として含まれる炭素および／または酸素を抑制することで、発光効率が向上した窒化物蛍光体を提供することにある。
本発明の他の目的は、窒化物蛍光体中に当該不純物として含まれる炭素および／または酸素を抑制して、当該蛍光体の発光効率を向上させることができる窒化物蛍光体の製造方法を提供することにある。
本発明の更に他の目的は、当該発光効率が向上した窒化物蛍光体を用いた光源及びＬＥＤを提供することにある。
An object of the present invention has been made in consideration of the above-described circumstances, and a nitride phosphor having improved luminous efficiency by suppressing carbon and / or oxygen contained as impurities in the nitride phosphor. Is to provide.
Another object of the present invention is to provide a method for producing a nitride phosphor capable of improving the luminous efficiency of the phosphor by suppressing carbon and / or oxygen contained as the impurity in the nitride phosphor. There is to do.
Still another object of the present invention is to provide a light source and an LED using a nitride phosphor with improved luminous efficiency.
第１の構成は、 一般式MAlSiN3:Euで表記され、MがII価の価数をとるMg、Ca、Sr、Ba、Znからなる群から選択された一種以上の元素、Alがアルミニウム、Siが珪素、Nが窒素、Euが付活剤となる元素であり、粉末状であると共に、炭素含有量が０．０８重量％より少なく、かつ、酸素含有量が３．０重量％より少ないことを特徴とする窒化物蛍光体である。
The first structure is represented by the general formula MAlSiN 3 : Eu, and M is one or more elements selected from the group consisting of Mg, Ca, Sr, Ba, and Zn, where Al has a valence of II, Al is aluminum, Si is silicon, N is nitrogen, Eu is an activator, is in powder form, has a carbon content of less than 0.08% by weight, and an oxygen content of less than 3.0% by weight. This is a nitride phosphor.
第２の構成は、上記粉末状の窒化物蛍光体の平均粒度が２０μｍ以下、０．１μｍ以上であることを特徴とする第１の構成に記載の窒化物蛍光体である。
The second configuration, the average particle size of the powder of the nitride phosphor is 20μm or less, a nitride phosphor according to the first configuration, characterized in that at 0.1μm or more.
第３の構成は、第１又は第２の構成のいずれかに記載の窒化物蛍光体の製造方法であって、上記窒化物蛍光体の原料を窒化ホウ素材質の焼成容器内に充填し、不活性雰囲気中で焼成して窒化物蛍光体を製造することを特徴とする窒化物蛍光体の製造方法である。
A third configuration is a method for manufacturing a nitride phosphor according to any one of the first and second configurations, in which a raw material for the nitride phosphor is filled in a firing container made of a boron nitride material. A nitride phosphor manufacturing method is characterized in that a nitride phosphor is manufactured by firing in an active atmosphere.
第４の構成は、第１又は第２の構成のいずれかに記載の窒化物蛍光体と、所定波長の光を発光する発光部とを有し、上記所定波長の光の一部を励起源とし、上記窒化物蛍光体を上記所定波長と異なる波長で発光させることを特徴とする光源である。
A fourth configuration includes the nitride phosphor according to any one of the first and second configurations and a light emitting unit that emits light of a predetermined wavelength, and a part of the light of the predetermined wavelength is an excitation source. And the nitride phosphor emits light at a wavelength different from the predetermined wavelength.
第５の構成は、上記所定波長が２５０〜５５０ｎｍの波長であることを特徴とする第４の構成に記載の光源である。
A fifth configuration is the light source according to the fourth configuration, wherein the predetermined wavelength is a wavelength of 250 to 550 nm.
第６の構成は、第１又は第２の構成のいずれかに記載の窒化物蛍光体と、所定波長の光を発光する発光部とを有し、上記所定波長の光の一部を励起源とし、上記窒化物蛍光体を上記所定波長と異なる波長で発光させることを特徴とするＬＥＤである。
A sixth configuration includes the nitride phosphor according to any one of the first and second configurations, and a light emitting unit that emits light of a predetermined wavelength, and a part of the light of the predetermined wavelength is an excitation source. And the nitride phosphor emits light at a wavelength different from the predetermined wavelength.
第７の構成は、上記所定波長が２５０〜５５０ｎｍの波長であることを特徴とする第６の構成に記載のＬＥＤである。
A seventh configuration is the LED according to the sixth configuration, wherein the predetermined wavelength is a wavelength of 250 to 550 nm.
第１又は第２の構成に係る窒化物蛍光体によれば、炭素含有量が０．０８重量％より少ない窒化物蛍光体、酸素含有量が３．０重量％より少ない窒化物蛍光体であることから、発光に寄与しない炭素と酸素の不純物含有量が少ないので、窒化物蛍光体の発光強度の低下を抑制でき、当該窒化物蛍光体の発光効率を向上させることができる。
The nitride phosphor according to the first or second configuration is a nitride phosphor having a carbon content of less than 0.08% by weight and a nitride phosphor having an oxygen content of less than 3.0% by weight. Therefore, since the impurity contents of carbon and oxygen that do not contribute to light emission are small, it is possible to suppress a decrease in the light emission intensity of the nitride phosphor, and to improve the light emission efficiency of the nitride phosphor.
また、一般式がＭ−Ａｌ−Ｓｉ−Ｎ：Ｚで表記され、ＭがII価の価数をとる一種以上の元素、Ａｌがアルミニウム、Ｓｉが珪素、Ｎが窒素、Ｚが付活剤となる元素であることから、紫外〜緑色の光を発光する発光部からの紫外〜緑色（波長域２５０〜５５０ｎｍ）の広い範囲の光に励起帯を有するので、発光効率を更に向上させることができる。
Further, the general formula is represented by M-Al-Si-N: Z, where M is one or more elements having a valence of II, Al is aluminum, Si is silicon, N is nitrogen, and Z is an activator. Since it has an excitation band in a wide range of light from ultraviolet to green (wavelength range 250 to 550 nm) from a light emitting part that emits ultraviolet to green light, the luminous efficiency can be further improved. .
第１または第２の構成に係る窒化物蛍光体が粉末状であることから、窒化物蛍光体の塗布または充填を容易に実施できる。更に、窒化物蛍光体の粉末の平均粒度が２０μｍ以下、０．１μｍ以上であることから、発光効率を向上させることができる。
Since the nitride phosphor according to the first or second configuration is in a powder form, it is possible to easily apply or fill the nitride phosphor. Furthermore, since the average particle size of the nitride phosphor powder is 20 μm or less and 0.1 μm or more, the luminous efficiency can be improved.
第３の構成に係る窒化物蛍光体の製造方法によれば、窒化物蛍光体の原料を窒化ホウ素材質の焼成容器内に充填し、不活性雰囲気中で焼成して窒化物蛍光体を製造することから、炭素および酸素の不純物含有量が少ない窒化物蛍光体を製造することができる。このように、発光に寄与しない不純物が少ない窒化物蛍光体を製造できるので、発光強度の低下を抑制でき、窒化物蛍光体の発光効率を向上させることができる。
According to the method for producing a nitride phosphor according to the third configuration, the nitride phosphor is filled in a firing vessel made of boron nitride and fired in an inert atmosphere to produce the nitride phosphor. As a result, a nitride phosphor having a low carbon and oxygen impurity content can be produced. Thus, since the nitride phosphor with few impurities that do not contribute to light emission can be manufactured, a decrease in emission intensity can be suppressed, and the light emission efficiency of the nitride phosphor can be improved.
第４または第５の構成に係る光源は、窒化物蛍光体が、発光部が発光する所定の広い波長域(２５０〜５５０ｎｍ)の光に励起帯を有して発光するため、これらの窒化物蛍光体と発光部との組み合わせにより、可視光または白色光を発光する発光効率の高い光源を得ることができる。
In the light source according to the fourth or fifth configuration, the nitride phosphor emits light having an excitation band in light of a predetermined wide wavelength range (250 to 550 nm) emitted from the light emitting unit. By combining the phosphor and the light emitting portion, a light source with high luminous efficiency that emits visible light or white light can be obtained.
第６または第７の構成に係るＬＥＤは、窒化物蛍光体が、発光部が発光する所定の広い波長域(２５０〜５５０ｎｍ)の光に励起帯を有して発光するため、これらの窒化物蛍光体と発光部との組み合わせにより、可視光または白色光を発光する発光効率の高いＬＥＤを得ることができる。
In the LED according to the sixth or seventh configuration, the nitride phosphor emits light having an excitation band in light of a predetermined wide wavelength range (250 to 550 nm) emitted from the light emitting unit. By combining the phosphor and the light emitting portion, an LED having high luminous efficiency that emits visible light or white light can be obtained.
以下、本発明を実施するための最良の形態を、図面に基づき説明する。
本発明に係る窒化物蛍光体として、一般式がＭ−Ａｌ−Ｓｉ−Ｎ：Ｚで表記される窒化物蛍光体であって、ＭがII価の価数をとる一種以上の元素、Ａｌがアルミニウム、Ｓｉが珪素、Ｎが窒素、Ｚが付活剤となる元素である窒化物蛍光体を例として説明する。そして当該窒化物蛍光体において、不純物である炭素含有量が０．０８重量％より少なく、不純物である酸素含有量が３．０重量％より少ないものである。この不純物炭素含有量０．０８重量％未満と不純物酸素含有量３．０重量％未満は、両者が満たされることが好ましいが、いずれか一方が満たされている場合でもよい。
The best mode for carrying out the present invention will be described below with reference to the drawings.
The nitride phosphor according to the present invention is a nitride phosphor represented by the general formula M-Al-Si-N: Z, wherein M is one or more elements having a valence of II, Al A nitride phosphor, which is aluminum, Si is silicon, N is nitrogen, and Z is an activator, will be described as an example. In the nitride phosphor, the carbon content as an impurity is less than 0.08% by weight and the oxygen content as an impurity is less than 3.0% by weight. Both the impurity carbon content of less than 0.08% by weight and the impurity oxygen content of less than 3.0% by weight are preferably satisfied, but either one may be satisfied.
不純物炭素含有量が０．０８重量％より少ない窒化物蛍光体、不純物酸素含有量が３．０重量％より少ない窒化物蛍光体は、いずれの場合も、発光に寄与しない炭素と酸素の不純物含有量が少ないので、発光強度を相対強度で表したとき、２５〜３０％程度の発光強度の低下を抑制でき、従って発光効率を向上させることができる。 Nitride phosphors with an impurity carbon content of less than 0.08% by weight and nitride phosphors with an impurity oxygen content of less than 3.0% by weight contain carbon and oxygen impurities that do not contribute to light emission in any case. Since the amount is small, when the emission intensity is expressed in relative intensity, a decrease in the emission intensity of about 25 to 30% can be suppressed, and thus the emission efficiency can be improved.
また、窒化物蛍光体は、一般式がＭ−Ａｌ−Ｓｉ−Ｎ：Ｚで表記され、ＭがII価の価数をとる一種以上の元素、Ａｌがアルミニウム、Ｓｉが珪素、Ｎが窒素、Ｚが付活剤となる元素であることから、紫外〜緑色の光を発光する発光部からの紫外〜緑色（波長域２５０〜５５０ｎｍ）の広い範囲の光に励起帯を有するので、発光効率を更に向上させることができる。 The nitride phosphor is represented by a general formula M-Al-Si-N: Z, where M is one or more elements having a valence of II, Al is aluminum, Si is silicon, N is nitrogen, Since Z is an element that acts as an activator, it has an excitation band in a wide range of light from ultraviolet to green (wavelength range 250 to 550 nm) from the light emitting part that emits ultraviolet to green light, so that the luminous efficiency is improved. Further improvement can be achieved.
より詳しくは、当該窒化物蛍光体を組成式MmAlaSibNn:Zで表記したとき、n=2/3m+a+4/3bの関係を有する窒化物蛍光体であることが好ましい。ｎ、ｍ、a、b、が当該関係を満たすとき、上述の窒化物蛍光体の母体構造が化学的に安定な構造をとり、当該母体構造中に、発光に寄与しない不純物相が生じにくくなるためである。さらに、m = a = b = 1となることで安定性は向上する。ただし、母体構造の組成式からの若干の組成のずれは許容される。 More specifically, when the nitride phosphor is represented by a composition formula MmAlaSibNn: Z, a nitride phosphor having a relationship of n = 2 / 3m + a + 4 / 3b is preferable. When n, m, a, and b satisfy the relationship, the host structure of the nitride phosphor described above has a chemically stable structure, and an impurity phase that does not contribute to light emission is less likely to occur in the host structure. Because. Furthermore, stability is improved when m = a = b = 1. However, a slight compositional deviation from the composition formula of the matrix structure is allowed.
上記Ｍは、Ｂｅ、Ｍｇ、Ｃａ、Ｓｒ、Ｂａ、Ｚｎ、Ｃｄ、Ｈｇから選択される少なくとも１つ以上の元素であることが好ましく、更には、Ｍｇ、Ｃａ、Ｓｒ、Ｂａ、Ｚｎから選択される少なくとも１つ以上の元素であることが好ましい。 M is preferably at least one element selected from Be, Mg, Ca, Sr, Ba, Zn, Cd, and Hg, and further selected from Mg, Ca, Sr, Ba, and Zn. Preferably, the element is at least one element.
上記Ｚは、希土類元素または遷移金属元素から選択される少なくとも1つ以上の元素であることが好ましいが、特にＥｕ、Ｍｎ、Ｓｍ、Ｃｅから選択される少なくとも1つ以上の元素であることが好ましい。中でもＥｕを用いると、窒化物蛍光体は橙色から赤色にかけての強い発光を示すため発光効率が高く、白色を発する光源(ＬＥＤ)用の窒化物蛍光体の付活剤としてより好ましい。 Z is preferably at least one element selected from rare earth elements or transition metal elements, and is particularly preferably at least one element selected from Eu, Mn, Sm, and Ce. . Among these, when Eu is used, the nitride phosphor exhibits strong light emission from orange to red, and thus has high luminous efficiency, and is more preferable as an activator of the nitride phosphor for a light source (LED) that emits white light.
本発明に係る窒化物蛍光体（以下、単に「蛍光体」と記載する場合がある。）は、塗布または充填の容易さを考慮して粉状体とされるが、この場合には、当該蛍光体粉体の平均粒径が２０μｍ以下であることが好ましい。これは、蛍光体粉体において発光は主に粒子表面で起こると考えられるため、平均粒径が２０μｍ以下であれば、粉体単位重量あたりの表面積を確保でき輝度の低下を回避できるからである。更に、当該粉体をペースト状とし、発光体素子等に塗布した場合にも当該粉体の密度を高めることができ、この観点からも輝度の低下を回避することができる。また、本発明者らの検討によると、詳細な理由は不明であるが、蛍光体粉末の発光効率の観点から、平均粒径が０．１μｍより大きいことが好ましいことも判明した。以上のことより、本発明に係る蛍光体粉体の平均粒径は、０．１μｍ以上２０μｍ以下であることが好ましい。 The nitride phosphor according to the present invention (hereinafter sometimes simply referred to as “phosphor”) is a powdery material in consideration of ease of application or filling. The average particle diameter of the phosphor powder is preferably 20 μm or less. This is because light emission is considered to occur mainly on the particle surface in the phosphor powder, and if the average particle size is 20 μm or less, a surface area per unit weight of the powder can be secured and a decrease in luminance can be avoided. . Furthermore, the density of the powder can be increased even when the powder is formed into a paste and applied to a light-emitting element or the like, and a decrease in luminance can be avoided also from this viewpoint. Further, according to the study by the present inventors, although the detailed reason is unknown, it has been found that the average particle size is preferably larger than 0.1 μm from the viewpoint of the luminous efficiency of the phosphor powder. From the above, the average particle diameter of the phosphor powder according to the present invention is preferably 0.1 μm or more and 20 μm or less.
本発明に係る蛍光体の製造方法は、蛍光体の原料を窒化ホウ素材質の焼成容器内に充填し、不活性雰囲気中で焼成して蛍光体を製造する。この蛍光体の製造方法を、蛍光体としてＣａＡｌＳｉＮ３：Ｅｕ（但し、Ｅｕ／（Ｃａ＋Ｅｕ）モル比＝０．０１５の場合）の製造を例として説明する。 In the method for producing a phosphor according to the present invention, a phosphor material is filled in a firing container made of boron nitride and fired in an inert atmosphere to produce the phosphor. This phosphor manufacturing method will be described by taking, as an example, the manufacture of CaAlSiN 3 : Eu (provided that Eu / (Ca + Eu) molar ratio = 0.015) as the phosphor.
まず、原料としてＣａ、Ａｌ、Ｓｉの窒化物として、それぞれＣａ３Ｎ２（２Ｎ）、ＡｌＮ（３Ｎ）、Ｓｉ３Ｎ４（３Ｎ）を準備する。Ｅｕ原料としては、Ｅｕ２Ｏ３（３Ｎ）を準備する。 First, Ca 3 N 2 (2N), AlN (3N), and Si 3 N 4 (3N) are prepared as raw materials of Ca, Al, and Si, respectively. Eu 2 O 3 (3N) is prepared as the Eu raw material.
これらの原料を、各元素のモル比がＣａ：Ａｌ：Ｓｉ：Ｅｕ＝０．９８５：１：１：０．０１５となるように秤量し混合する。((Ｃａ+Ｅｕ)：Ａｌ：Ｓｉ：＝1：１：１となる。)当該混合は、乳鉢等を用いる通常の混合方法で良いが、窒素等の不活性雰囲気下のグローブボックス内で操作することが便宜である。 These raw materials are weighed and mixed so that the molar ratio of each element is Ca: Al: Si: Eu = 0.985: 1: 1: 0.015. ((Ca + Eu): Al: Si: = 1: 1: 1) The mixing may be performed by a normal mixing method using a mortar or the like, but operated in a glove box under an inert atmosphere such as nitrogen. It is convenient to do.
当該混合を不活性雰囲気下のグローブボックス内で操作する理由は、この操作を大気中おこなうと、上記原料の酸化や分解により母体構成元素中に含まれる酸素濃度の比率が崩れ、発光特性が低下する可能性がある上、蛍光体の目的組成からずれてしまうことが考えられるためである。更に、各原料元素の窒化物は水分の影響を受けやすいため、不活性ガスは水分を十分取り除いたものを使用するのが良い。各原料元素として窒化物原料を用いる場合、原料の分解を回避するため混合方式は乾式混合が好ましく、ボールミルや乳鉢等を用いる通常の乾式混合方法でよい。 The reason for operating the mixing in a glove box under an inert atmosphere is that if this operation is performed in the atmosphere, the ratio of the oxygen concentration contained in the matrix constituent elements collapses due to oxidation and decomposition of the above raw materials, resulting in a decrease in light emission characteristics. This is because there is a possibility of deviating from the target composition of the phosphor. Furthermore, since the nitride of each raw material element is easily affected by moisture, it is preferable to use an inert gas from which moisture has been sufficiently removed. When a nitride raw material is used as each raw material element, dry mixing is preferable as a mixing method in order to avoid decomposition of the raw material, and a normal dry mixing method using a ball mill, a mortar, or the like may be used.
混合が完了した原料を、焼成容器として窒化ホウ素製のるつぼに充填し、窒素等の不活性雰囲気中で１５００℃まで１５℃／ｍｉｎ．の昇温速度で昇温し、１５００℃で３時間保持し焼成する。焼成温度は１０００℃以上、好ましくは１４００℃以上であればよい。保持時間は焼成温度が高いほど焼成が迅速に進むため短くできる。焼成温度が低くても、長時間保持することにより目的の発光特性を得ることができる。焼成時間が長いほど粒子成長が進み、粒子形状が大きくなるため、目的の粒子サイズによって任意の焼成時間を設定すればよい。 The mixed raw material is filled in a boron nitride crucible as a firing container and is heated to 1500 ° C. in an inert atmosphere such as nitrogen at 15 ° C./min. The temperature is increased at a temperature increase rate of 1,5 ° C. and held at 1500 ° C. for 3 hours for firing. The firing temperature may be 1000 ° C. or higher, preferably 1400 ° C. or higher. The holding time can be shortened because the firing proceeds more rapidly as the firing temperature is higher. Even if the firing temperature is low, the desired light emission characteristics can be obtained by holding for a long time. As the firing time is longer, the particle growth proceeds and the particle shape becomes larger. Therefore, an arbitrary firing time may be set according to the target particle size.
ここで、本発明者らは、蛍光体の原料を焼成する焼成容器(例えば、るつぼ)として、例えばカーボン製の焼成容器を使用して焼成した場合には、カーボン製の焼成容器から焼成される蛍光体中に不純物として炭素が混入し、蛍光体の発光強度が低下するおそれがあることに想到した。本発明者らの検討によると、蛍光体中に含まれる炭素の量が０．０８重量％以上となると蛍光体の発光強度が低下し始めることを見出した。また、本発明者らは、アルミナ製の焼成容器を使用して焼成した場合には、アルミナ製の焼成容器から焼成される蛍光体中に不純物として酸素が拡散し、蛍光体の発光強度が低下するおそれがあることに想到した。本発明者らの検討によると、蛍光体中に含まれる酸素の量が３．０重量％以上となると蛍光体の発光強度が低下し始めることを見出した。 Here, the present inventors, as a firing container (for example, a crucible) for firing a phosphor material, are fired from a carbon firing container when fired using, for example, a carbon firing container. It has been conceived that carbon may be mixed as an impurity in the phosphor and the emission intensity of the phosphor may be reduced. According to the study by the present inventors, it has been found that when the amount of carbon contained in the phosphor becomes 0.08% by weight or more, the emission intensity of the phosphor starts to decrease. In addition, when the present inventors baked using an alumina firing container, oxygen diffuses as an impurity in the phosphor fired from the alumina firing container, and the emission intensity of the phosphor decreases. I thought that there was a risk of doing. According to the study by the present inventors, it has been found that when the amount of oxygen contained in the phosphor becomes 3.0% by weight or more, the emission intensity of the phosphor starts to decrease.
そして本発明者らは、窒化ホウ素製の焼成容器を用いて蛍光体を焼成して製造することで、発光に寄与しない不純物炭素含有量と不純物酸素含有量の少ない蛍光体を製造することができ、発光強度の低下を抑制でき、発光体の発光効率を向上させることができることに想到した。 The inventors of the present invention can produce a phosphor with a low content of impurity carbon and low content of impurity oxygen that does not contribute to light emission by firing the phosphor using a firing container made of boron nitride. Thus, it has been conceived that a decrease in emission intensity can be suppressed and the luminous efficiency of the luminous body can be improved.
そこで、焼成容器として窒化ホウ素製の焼成容器を用い、焼成が完了した後、１５００℃から２００℃まで１時間で冷却し、さらに室温まで冷却した後、乳鉢、ボールミル等の粉砕手段を用いて所定（好ましくは２０μｍ〜１μｍ）の平均粒径となるように粉砕し、組成式Ｃａ０．９８５ＳｉＡｌＮ３：Ｅｕ０．０１５の蛍光体を製造する。 Therefore, a boron nitride firing container is used as the firing container, and after firing is completed, the temperature is cooled from 1500 ° C. to 200 ° C. in 1 hour, and further cooled to room temperature, and then predetermined using pulverizing means such as a mortar and ball mill. (preferably 20Myuemu～1myuemu) was ground to an average particle size of the composition formula Ca 0.985 SiAlN 3: preparing a phosphor of Eu 0.015.
Ｅｕ／（Ｃａ＋Ｅｕ）モル比の設定値が変動した場合も、各原料の仕込時の配合量を所定の組成式に合わせることで、同様の製造方法により所定の組成の蛍光体を製造することができる。得られた蛍光体はいずれも炭素含有量が０．０８重量％より少なく、酸素含有量が３．０重量％より少ないものであった。 Even when the set value of Eu / (Ca + Eu) molar ratio fluctuates, a phosphor having a predetermined composition can be manufactured by a similar manufacturing method by adjusting the blending amount of each raw material to a predetermined composition formula. it can. All of the obtained phosphors had a carbon content of less than 0.08% by weight and an oxygen content of less than 3.0% by weight.
粉末状となった本発明に係る蛍光体は、公知の方法で発光部（特には、発光波長域２５０〜５５０ｎｍのいずれかの発光をおこなう発光部）と組み合わせることで、当該発光部が発光する広い範囲の波長域の光に励起帯を有して発光するので、可視光または白色光を発光する発光効率の高い光源を得ることができる。特に、発光部として発光波長域２５０〜５５０ｎｍのいずれかの発光をおこなうＬＥＤと、公知の方法により組み合わせることで、可視光または白色光を発光する発光効率の高いＬＥＤを得ることができる。
従って、この光源(ＬＥＤ)をＣＲＴ、ＰＤＰ等のディスプレイ装置や、蛍光灯等の照明装置の多様な光源として用いることができる。
The phosphor according to the present invention in a powder form is combined with a light emitting part (particularly, a light emitting part that emits light in any of the light emission wavelength ranges of 250 to 550 nm) by a known method, so that the light emitting part emits light. Since light having an excitation band is emitted in light in a wide wavelength range, a light source with high emission efficiency that emits visible light or white light can be obtained. In particular, an LED that emits visible light or white light can be obtained by combining an LED that emits light in the emission wavelength range of 250 to 550 nm as a light emitting unit with a known method.
Therefore, this light source (LED) can be used as various light sources for display devices such as CRT and PDP and illumination devices such as fluorescent lamps.
以下、実施例に基づいて、本発明をより具体的に説明する。
（実施例１）
市販のＣａ３Ｎ２（２Ｎ）、ＡｌＮ（３Ｎ）、Ｓｉ３Ｎ４（３Ｎ）、Ｅｕ２Ｏ３（３Ｎ）を準備し、各元素のモル比がＣａ：Ａｌ：Ｓｉ：Ｅｕ＝０．９８５：１：１：０．０１５となるように各原料を秤量し、窒素雰囲気下のグローブボックス中において乳鉢を用いて混合した。混合した原料を窒化ホウ素製のるつぼに充填し、窒素雰囲気中で１５００℃まで１５℃／ｍｉｎ．の昇温速度で昇温し、１５００℃で３時間保持し焼成した後、１５００℃から２００℃まで１時間で冷却し、組成式Ｃａ０．９８５ＳｉＡｌＮ３：Ｅｕ０．０１５の蛍光体を得た。
得られた蛍光体粉末に４６０ｎｍの単色光を照射したところ、図1に示すように、６５６ｎｍに発光ピークを有する赤色発光を示した。また、化学分析により得られた不純物炭素濃度、不純物酸素濃度はそれぞれ０．０４３重量％、２．０９重量％であった。
Hereinafter, based on an Example, this invention is demonstrated more concretely.
Example 1
Commercially available Ca 3 N 2 (2N), AlN (3N), Si 3 N 4 (3N), and Eu 2 O 3 (3N) were prepared, and the molar ratio of each element was Ca: Al: Si: Eu = 0. Each raw material was weighed so that it would become 985: 1: 1: 0.015, and it mixed using the mortar in the glove box of nitrogen atmosphere. The mixed raw material is filled in a crucible made of boron nitride, and 15 ° C./min. Was heated at 1500 ° C. for 3 hours and fired, and then cooled from 1500 ° C. to 200 ° C. for 1 hour to obtain a phosphor of composition formula Ca 0.985 SiAlN 3 : Eu 0.015. It was.
When the obtained phosphor powder was irradiated with monochromatic light of 460 nm, red light emission having an emission peak at 656 nm was shown as shown in FIG. The impurity carbon concentration and impurity oxygen concentration obtained by chemical analysis were 0.043 wt% and 2.09 wt%, respectively.
（比較例１）
焼成に使用する容器を窒化ホウ素製のるつぼからカーボン製のるつぼに変更した他は、実施例１と同様の条件で蛍光体を作製した。得られた蛍光体粉末に４６０ｎｍの単色光を照射したところ、６５０ｎｍに発光ピークを有する赤色発光を示した。図１に本比較例で作製した蛍光体の相対発光強度、並びに化学分析により得られた不純物炭素濃度及び不純物酸素濃度を示す。
図１及び図２に示すように、焼成容器にカーボン製るつぼを使用して作製した蛍光体は、窒化ホウ素製のるつぼを使用して作製した実施例１の蛍光体と比べて発光強度が約２６％低下する結果となった。カーボン製るつぼを使用して作製した蛍光体は、不純物炭素量が０．０８０重量％に増加していることから、当該不純物炭素が発光強度を低下させているものと考えられる。
(Comparative Example 1)
A phosphor was produced under the same conditions as in Example 1 except that the container used for firing was changed from a boron nitride crucible to a carbon crucible. When the obtained phosphor powder was irradiated with monochromatic light of 460 nm, it showed red light emission having an emission peak at 650 nm. FIG. 1 shows the relative emission intensity of the phosphor produced in this comparative example, and the impurity carbon concentration and impurity oxygen concentration obtained by chemical analysis.
As shown in FIGS. 1 and 2, the phosphor produced using a carbon crucible for the firing container has a light emission intensity of about 1% compared to the phosphor of Example 1 produced using a boron nitride crucible. The result decreased by 26%. Since the phosphor produced using a carbon crucible has an impurity carbon content increased to 0.080% by weight, it is considered that the impurity carbon reduces the emission intensity.
（比較例２）
焼成に使用する容器を窒化ホウ素製のるつぼからアルミナ製のるつぼに変更した他は、実施例１と同様の条件で蛍光体を作製した。得られた蛍光体粉末に４６０ｎｍの単色光を照射したところ、６５２ｎｍに発光ピークを有する赤色発光を示した。図１に本比較例で作製した蛍光体の相対発光強度、並びに化学分析により得られた不純物炭素濃度及び不純物酸素濃度を示す。
図１及び図２に示すように、焼成容器にアルミナ製るつぼを使用して作製した蛍光体は、窒化ホウ素製のるつぼを使用して作製した実施例１の蛍光体と比べて発光強度が約２０％低下する結果となった。アルミナ製るつぼを使用して作製した蛍光体は、不純物酸素量が３．０２重量％に増加していることから、当該不純物酸素が発光強度を低下させているものと考えられる。
(Comparative Example 2)
A phosphor was produced under the same conditions as in Example 1 except that the container used for firing was changed from a boron nitride crucible to an alumina crucible. When the obtained phosphor powder was irradiated with monochromatic light of 460 nm, it showed red light emission having an emission peak at 652 nm. FIG. 1 shows the relative emission intensity of the phosphor produced in this comparative example, and the impurity carbon concentration and impurity oxygen concentration obtained by chemical analysis.
As shown in FIGS. 1 and 2, the phosphor produced using the alumina crucible for the firing container has a light emission intensity of about 1% compared to the phosphor of Example 1 produced using the boron nitride crucible. The result decreased by 20%. Since the phosphor produced using the crucible made of alumina has an impurity oxygen amount increased to 3.02% by weight, the impurity oxygen is considered to decrease the emission intensity.
以上、本発明を上記実施の形態に基づいて説明したが、本発明はこれに限定されるものではない。 As mentioned above, although this invention was demonstrated based on the said embodiment, this invention is not limited to this.
Claims (7)
上記窒化物蛍光体の原料を窒化ホウ素材質の焼成容器内に充填し、不活性雰囲気中で焼成して窒化物蛍光体を製造することを特徴とする窒化物蛍光体の製造方法。 A method for producing a nitride phosphor according to claim 1 or 2 ,
A nitride phosphor is produced by filling a nitride phosphor material into a firing vessel made of boron nitride and firing in an inert atmosphere to produce a nitride phosphor.
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| JP2004207271A JP5016187B2 (en) | 2004-07-14 | 2004-07-14 | Nitride phosphor, method for producing nitride phosphor, light source and LED using the nitride phosphor |
| TW094105848A TWI262609B (en) | 2004-02-27 | 2005-02-25 | Phosphor and manufacturing method thereof, and light source, LED using said phosphor |
| KR1020050016250A KR100702757B1 (en) | 2004-02-27 | 2005-02-26 | Phosphor and manufacturing method thereof, and light source, led using said phosphor |
| CNB2005100525227A CN100340631C (en) | 2004-02-27 | 2005-02-28 | Phosphor and manufacturing method thereof, and led light source using said phosphor |
| DE602005014296T DE602005014296D1 (en) | 2004-02-27 | 2005-02-28 | Phosphor and its preparation and LED light source using this phosphor |
| EP05004375A EP1568753B1 (en) | 2004-02-27 | 2005-02-28 | Phosphor and manufacturing method thereof, and LED light source using said phosphor |
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