TWI396303B - Fabrication methods for fluorescent powders on substrate and white light led devices - Google Patents

Description

Method for manufacturing substrate with fluorescent powder and white LED light source element

The present invention relates to a method for producing a phosphor powder substrate, and more particularly to a method for producing a phosphor powder ceramic glass substrate applied to a white light emitting device.

The conventional solid-state semiconductor white light source mainly has the following three methods. The first white light source is a white light-emitting module composed of red, blue and green light-emitting diode crystal grains, which has the advantages of high luminous efficiency and high color rendering, but at the same time Also due to different color crystal grains, it is necessary to match different epitaxial materials, and the voltage characteristics are also different. Therefore, the manufacturing cost is high, the control circuit design is complicated, and the light mixing adjustment is not easy.

The second white light source is a blue light emitting diode that excites yellow yttrium aluminum garnet (YAG) phosphor to produce white light. This method is the mainstream trend in the current market. On the periphery of the blue light-emitting diode chip, an optical glue mixed with yellow YAG phosphor powder is filled, and the blue light emitted by the blue light-emitting diode chip has a wavelength of about 400 to 530 nm. The yellow light is generated by the light emitted by the blue light emitting diode chip to generate yellow light. At the same time, part of the blue light is emitted. This part of the blue light is combined with the yellow light emitted by the phosphor powder, which forms a white light of two wavelengths mixed with blue and yellow. However, such a white light-emitting diode combined with a blue light-emitting diode chip and a yellow light-emitting phosphor has the following disadvantages: First, since blue light accounts for most of the light-emitting spectrum, color temperature is high and The phenomenon of uneven illumination caused by dispensing. Second, the wavelength of the blue light emitting diode will change with the temperature increase. The change causes the color control of the white light source to be difficult, and even causes the problem of heat dissipation to be difficult. Third, due to the weak red spectrum of the luminescence, the color rendering is poor.

The third type of white light source is a blue, green, and red phosphor powder uniformly mixed with a certain proportion of the transparent optical glue excited by the ultraviolet light emitting diode, and three wavelengths of white light can be obtained after excitation. The three-wavelength white light emitting diode has the advantages of high color rendering, but has the disadvantages of insufficient luminous efficiency and easy aging of the transparent optical adhesive.

Furthermore, in terms of white LED packaging technology, when developing high-power and large-area LED lighting modules, the heat dissipation problem will seriously affect the component life. The commonly used dispensing, sealing and molding processes on current LED packages Because the epoxy resin used is easy to thicken during use, it is difficult to control defects such as bubbles, lack of materials, black spots, and phosphor powder precipitation in the fluorescent glue, so that the uniformity of illumination cannot be consistent, and easy Causes the chromatic aberration of the product.

The embodiment of the invention provides a method for manufacturing a light-emitting component for a white LED light source by combining a ceramic glass flux and a phosphor powder material, and applying the same to a glass or ceramic substrate.

An embodiment of the present invention provides a method for manufacturing a substrate with phosphor powder, comprising: providing a phosphor powder and a flux, and uniformly mixing the same; and coating the mixed phosphor powder and the flux to become a semi-molten one glass body; the glass body is ground into a fluorescent glass powder, and the fluorescent glass powder is coated on a substrate; and the fluorescent glass powder is heated to form a glass body A fluorescent film is on the substrate.

The embodiment of the invention further provides a method for manufacturing a white LED light source component, comprising: providing a phosphor powder and a flux, and uniformly mixing the same; and coating the mixed phosphor powder and the flux to make it a half a molten glass body; the glass body is ground into a fluorescent glass powder, and the fluorescent glass powder is coated on a substrate; the fluorescent glass powder is heated to form a fluorescent film on the substrate; cutting The substrate having a fluorescent film is of a predetermined size and combined with an LED wafer.

In order to make the invention more apparent, the following detailed description of the embodiments and the accompanying drawings are as follows:

The following is a detailed description of the embodiments and examples accompanying the drawings, which are the basis of the present invention. In the drawings or the description of the specification, the same drawing numbers are used for similar or identical parts. In the drawings, the shape or thickness of the embodiment may be expanded and simplified or conveniently indicated. In addition, the components of the drawings will be described separately, and it is noted that the components not shown or described in the drawings are known to those of ordinary skill in the art, and in particular, The examples are merely illustrative of specific ways of using the invention and are not intended to limit the invention.

One embodiment of the present invention provides a method of fabricating a white light LED light source phosphor powder ceramic substrate component. More specifically, using ceramic glass flux with various phosphor powders on glass or ceramic substrates to make Become a high-power white LED lighting component.

1 is a flow chart showing the manufacture of a white LED light source element in accordance with an embodiment of the present invention. Referring to Fig. 1, first, a phosphor (step S10b) and a flux (step S10b) are separately provided and uniformly mixed in a certain ratio. Next, the mixed phosphor powder and the flux are baked (step S20), and quenched to form a semi-molten one glass body (step S30). The glass body is ground into a phosphorescent glass powder (step S40), and the phosphor glass powder is applied onto a substrate (step S50). The phosphor glass powder is heated to form a fluorescent film on the substrate (step S60). The substrate having the fluorescent film is cut into a predetermined size and combined with a blue LED chip package to form a white LED light source element (step S70).

An embodiment of the present invention provides a method for fabricating a phosphor powder ceramic substrate, which can be used as an optical converter for a white LED light source component. According to an embodiment of the present invention, the ceramic frit is mixed with the phosphor material, and after being mixed in an appropriate ratio, the mixture is heat-treated into a uniform molten glass, and the molten material is water quenched to become a uniform state glass. After the glass is ground, dried, pulverized, and sieved, a fluorescent glass pigment is obtained.

The fluorescent glass pigment is coated on a substrate, for example, by a coating method, a screen printing method, a transfer method, or an inkjet method, on a ceramic or glass substrate to achieve a uniform fluorescent coating layer. The heat treatment allows the coating layer and the substrate to be sufficiently combined to obtain a desired phosphor powder ceramic substrate, and the substrate is cut according to the required size requirements of the white LED package, and assembled, and can be applied to the white LED light source package. Time lighting component.

According to an embodiment of the present invention, the ceramic frit flux is mainly characterized by lead-free and cadmium-free, and a composition formula which does not react with the phosphor powder during heat treatment, and the composition range (weight percentage of oxide) is, for example, SiO _{2 .} : 30~65%; Al ₂ O ₃ : 0.1~12%; K ₂ O+Na ₂ O: 4~10%; ZnO: 0.1~30%; B ₂ O ₃ : 6~20%; ZrO ₂ : 0.1 ~7%; Li ₂ O: 3~11%; La ₂ O ₃ : 0.1~5%; BaO: 0.1~5%; CaO: 0.1~8%; TiO ₂ : 0.1~5%, according to the actual formula The ceramic glass flux powder can be obtained after the raw materials are mixed, melted, quenched, ground, sieved, dried, pulverized, and the like.

Furthermore, the phosphor material is a fluorescent material which can absorb and emit radiation in a wavelength range of 254 to 500 nm, and includes at least yellow yttrium aluminum garnet (YAG) and yellow yttrium aluminum garnet. (Terbium Aluminum Garnet, TAG for short), yellow silicate (Silicate), for example, a composition having a crystalline phase of Sr ₂ SiO ₄ or Sr ₃ SiO ₅ , a sulfide (Sulfate), a nitride (Nitrate), or the like random combination. More specifically, phosphors which can be excited in the ultraviolet (UV) or violet, blue, and fluorescent light can be applied to embodiments of the present invention. According to the purpose of white light LED dimming, the materials used in combination with the proportion of use are combined.

According to another embodiment of the present invention, the ceramic glass frit powder and the phosphor powder are mixed after being appropriately proportioned, and are not limited to the mixing mode, and any form of iron contamination should be avoided in the process. The mixture after completion of the mixing is placed in a refractory crucible, and heat treatment is performed depending on the composition conditions of the glass ceramic colorant, for example, at a temperature ranging from 700 ° C to 1000 ° C. The heat treatment time is 4 to 10 minutes. After the heat treatment, the mixture becomes a semi-molten homogeneous glass phase, and at this time, it is rapidly poured into cold water for quenching.

Then, after removing the water, the quenched solid material is ground by a wet ball milling method to a fineness of a 400-mesh standard sieve, and after drying and pulverizing, the desired fluorescent glass is obtained. pigment.

The above-mentioned fluorescent pigment is formed on Al ₂ O ₃ , AlN or a glass or sapphire substrate by coating, screen printing, transfer, inkjet or the like to form a uniform fluorescent coating layer, and is coated. The entire substrate of the cloth layer is placed in an electric furnace, and the temperature thereof is determined by the softening point temperature measured by the composition of the ceramic glass flux, for example, by heating at a temperature ranging from 550 ° C to 1000 ° C.

The fired ceramic substrate after the firing is cut and packaged according to the required size requirements of the white LED package, and then can be applied to the light-emitting component of the white LED light source package.

2 is a cross-sectional view showing a white LED light source package according to an embodiment of the present invention. As previously described, the substrate 100 with the phosphor film 120 is sized and combined with a blue LED chip 200 package to form a white LED source element. The blue light BL emitted from the blue LED chip 200 is converted into white light WL through the substrate 100 having the fluorescent film 120. Two specific embodiments will be exemplified below to explain a method of manufacturing the white LED light source package of the present invention.

Specific embodiment 1

Take 60g ceramic low-temperature flux powder, the composition is SiO ₂ : 50~65%; Al ₂ O ₃ : 8~12%; Na ₂ O: 2~5%; K ₂ O: 2~5%; B ₂ O ₃ : 6~10%; ZrO ₂ : 4~7%; Li ₂ O: 4~8%; La ₂ O ₃ : 2~5%; BaO: 2~5%, and 40g YAG fluorescence The powder, after being uniformly mixed uniformly, was placed in a mullite crucible and heated at 950 ° C. After holding the temperature for eight minutes, the mixture was melted into a semi-molten homogeneous mixture and quenched into cold water. After quenching, the semi-molten state mixture is taken out and ground to a particle size which can pass through a 400 mesh screen, and the slurry after completion of the grinding is dried and pulverized for use.

100 g of the above-mentioned finished powder was taken, and 60 g of ink (for example, Hereaus, Silk Screen Oil HT-590015) was added for blending. In order to make the dispersion uniform, a stirrer or a triaxial drum may be used. The mixed grease is printed on the alumina substrate in a 51T full ink screen, and the thickness of the alumina substrate is, for example, 0.1 to 0.3 mm. Next, the printed alumina substrate was placed in a high-temperature furnace, and after raising the temperature to 830 ° C and holding the temperature for five minutes, the heating was stopped, and the mixture was naturally cooled at room temperature. After cooling, the alumina substrate with the surface of the phosphor powder is removed and cut into a size of 2900 μm × 2900 μm, and silver paste is attached to the module integrating the four 1.225 W blue LED chips (blue wavelength range) 400~530nm), you can get high-power white LED light source with uniform brightness and good heat dissipation between different products.

Specific embodiment 2

Take 600g ceramic low-temperature flux powder 70g, its composition is SiO ₂ : 30~40%; Al ₂ O ₃ : 0.1~12%; K ₂ O: 2~5; Na ₂ O: 2~5%; ZnO: 25~30%; B ₂ O ₃ : 15~20%; ZrO ₂ : 2~5%; Li ₂ O: 8~11%; CaO: 5~8%; TiO ₂ : 2~5%, with 30g Silicate fluorescent powder (such as LWB, Fluoroscent Powder, Type: LP-F560-20), fully mixed, placed in mullite, heated at 750 ° C, heated for five minutes, will be melted The homogeneous mixture in a semi-molten state is poured into cold water and quenched. After quenching, the semi-molten state mixture is taken out and ground to a particle size which can pass through a 400 mesh screen. After the grinding is completed, the slurry is dried and pulverized for use. .

100 g of the above-mentioned finished powder was taken, and 65 g of ink (for example, Hereaus, Silk Screen Oil HT-590015) was added for blending. In order to make the dispersion uniform, a stirrer or a triaxial drum may be used. The mixed paste is printed on a glass substrate having a thickness of 0.2 to 1.0 mm using a 100T full ink screen. After the printing, the glass substrate was placed in a high-temperature furnace, heated to 610 ° C, and then kept at a constant temperature for five minutes, and the heating was stopped, and the mixture was naturally cooled at room temperature. After cooling, the glass substrate having the surface of the phosphor powder is fired and cut into a size of 1000 μm×1000 μm, and the silver paste is attached to the blue LED chip (blue light wavelength range 400~530 nm), and each can be obtained. A white LED light source with uniform brightness and good heat dissipation between products.

The present invention has been disclosed in the above preferred embodiments, and is not intended to limit the scope of the present invention. Any one of ordinary skill in the art can make a few changes without departing from the spirit and scope of the invention. The scope of protection of the present invention is therefore defined by the scope of the appended claims.

Steps for manufacturing S10a-S70‧‧‧ white LED light source components

100‧‧‧Substrate

120‧‧‧Flame film

200‧‧‧Blue LED chip

BL‧‧‧Blue

WL‧‧‧White light

1 is a flow chart showing the manufacture of a white LED light source element in accordance with an embodiment of the present invention.

2 is a cross-sectional view showing a white LED light source package according to an embodiment of the present invention.

Steps for manufacturing S10a-S70‧‧‧ white LED light source components

Claims (14)

A method for manufacturing a substrate with phosphor powder, comprising: providing a phosphor powder and a flux and uniformly mixing the same; and coating the mixed phosphor powder and the flux to form a semi-molten glass body The glass body is ground into a phosphorescent glass powder, and the phosphor glass powder is coated on a substrate; and the phosphor glass powder is heated to form a fluorescent film on the substrate. The method for manufacturing a phosphor-containing substrate according to claim 1, wherein the phosphor powder is a fluorescent material that absorbs and emits a spectrum in a wavelength range of 254 to 500 nm, and includes a yellow yttrium aluminum pomegranate. Stone (YAG), a yellow yttrium aluminum garnet (TAG), a yellow silicate (Silicate), a monosulfide (Sulfate) and a nitride (Nitrate) or any combination of the above. The method for manufacturing a phosphor-containing substrate according to claim 1, wherein the flux material comprises a lead-free and cadmium-free ceramic glass flux, and the composition of the fluorescent powder does not react during heat treatment. . The method for manufacturing a phosphor powder-containing substrate according to claim 3, wherein the composition of the lead-free and cadmium-free ceramic glass flux comprises: SiO ₂ : 30 to 65%; and Al ₂ O ₃ : 0.1 to 12% ; K ₂ O+Na ₂ O: 4~10%; ZnO: 0.1~30%; B ₂ O ₃ : 6~20%; ZrO ₂ : 0.1~7%; Li ₂ O: 3~11%; La ₂ O ₃ : 0.1 to 5%; BaO: 0.1 to 5%; CaO: 0.1 to 8%; TiO ₂ : 0.1 to 5%. The method for manufacturing a phosphor-containing substrate according to claim 1, wherein the substrate comprises a ceramic substrate or a glass substrate. The method for producing a phosphor-containing substrate according to claim 1, wherein the ceramic substrate comprises Al ₂ O ₃ , AlN, and sapphire. The method for producing a phosphor-containing substrate according to claim 1, wherein the step of applying the phosphor powder comprises a coating method, a screen printing method, a transfer method, and an inkjet printing method. law. A method for manufacturing a white light LED light source component, comprising: providing a phosphor powder and a flux and uniformly mixing the same; and coating the mixed phosphor powder and the flux to form a semi-molten glass body; The glass body is ground into a phosphorescent glass powder, and the fluorescent glass powder is coated on a substrate; the fluorescent glass powder is heated to form a fluorescent film on the substrate; and the fluorescent film is cut The substrate is of a predetermined size and combined with an ultraviolet (UV), violet or blue LED wafer. The method for manufacturing a white light LED light source device according to claim 8, wherein the phosphor powder is made of a fluorescent material having absorption and emission spectrum in a wavelength range of 254 to 500 nm, which comprises a yellow yttrium aluminum garnet ( YAG), a yellow yttrium aluminum garnet (TAG), a yellow silicate (Silicate), a monosulfide (Sulfate) and a nitride (Nitrate) or any combination of the above. The method for manufacturing a white light LED light source component according to claim 8, wherein the flux material comprises a lead-free and cadmium-free ceramic glass flux and is formulated without reacting with the phosphor powder during heat treatment. The method for manufacturing a white light LED light source component according to claim 10, wherein the composition of the lead-free and cadmium-free ceramic glass flux comprises: SiO ₂ : 30 to 65%; Al ₂ O ₃ : 0.1 to 12%; ₂ O+Na ₂ O: 4~10%; ZnO: 0.1~30%; B ₂ O ₃ : 6~20%; ZrO ₂ : 0.1~7%; Li ₂ O: 3~11%; La ₂ O ₃ : 0.1~5%; BaO: 0.1~5%; CaO: 0.1~8%; TiO ₂ : 0.1~5%. The method of manufacturing a white LED light source component according to claim 8, wherein the substrate comprises a ceramic substrate or a glass substrate. The method of manufacturing a white light LED light source element according to claim 8, wherein the ceramic substrate comprises Al ₂ O ₃ and AlN and sapphire. The method for producing a white light LED light source device according to claim 8, wherein the step of applying the phosphor powder comprises a coating method, a screen printing method, a transfer method, and an inkjet printing method.