TWI628812B - Method for manufacturing solid state light emitter - Google Patents

Abstract

A method for manufacturing a solid-state light-emitting body is different from a conventional solid-state light-emitting body in which a light-emitting powder is doped into a filler material by a high-temperature calcination method, and the light-emitting powder is mixed with an inorganic powder or an organic powder. The mixed liquid can be formed into a solid-state illuminant by using a perfusion method, and the method can be carried out at a relatively low temperature, without high energy consumption and high equipment cost, and is easy to form at a low temperature, and is not easy to damage the structure of the luminescent powder itself in the process. The characteristics do not cause a decrease in luminous efficiency. Therefore, the solid state light emitter prepared by the invention has excellent high temperature resistance, can effectively prevent high temperature cracking caused by long-term illumination of the light-emitting element, and contributes to prolongation of service life and improvement of reliability.

Description

Method for manufacturing solid state light emitter

The present invention relates to a luminescent material, and more particularly to a method of producing a solid illuminant that can maintain material properties by low temperature molding.

In the conventional white light-emitting device manufacturing process, the sealant mixed with the phosphor powder and the glue is uniformly applied to the surface of the light-emitting diode (LED) by a coating method such as dispensing or screen printing, and then packaged and formed. For example, in the method for fabricating a white light emitting diode disclosed in Taiwan Patent No. 583777, a colloidal powder having a phosphor powder is applied to the surface of the light emitting diode and around the surface by a screen printing method, and then baked and hardened. And then molded. However, the mixing and coating process of the phosphor powder and the glue is complicated and time consuming, and it is easy to cause a problem of uneven distribution of the phosphor powder.

Therefore, a solid phosphor which can replace a sealant which is a mixture of glue and phosphor powder has recently been developed. For example, a method for fabricating a white light-emitting element disclosed in Japanese Patent Publication No. 201440255 and No. 201503416, which replaces a sealant formed by mixing a glue and a fluorescent powder by a solid phosphor; The light body is a ceramic phosphor composed of a ceramic material and a phosphor powder, or the solid phosphor is a glass phosphor composed of a glass material and a phosphor powder. The solid-state phosphor is simple and time-saving, and there is no problem of uneven distribution of the phosphor powder to improve the reliability and service life of the white light-emitting element.

However, limited to the current technology, the production method of the solid phosphor needs to be carried out in a high-temperature environment and cumbersome steps. In the above-mentioned patent case, it is fluorescent when the ceramic material or the glass material is calcined. The powder is added to a ceramic material or a glass material to be uniformly distributed or doped to form a ceramic phosphor or a glass phosphor. Due to the high temperature process, the lattice structure of the phosphor powder may be damaged, resulting in changes in the luminescence properties, such as the wavelength shift of the luminescence and the decrease in the luminescence efficiency.

In view of this, the applicant of the present invention specially developed a method for manufacturing a solid-state light-emitting body, which can be performed under simple and low-temperature operating conditions without damaging the lattice structure of the luminescent material and affecting its luminescent properties. This solid-state illuminator has high temperature resistance and can withstand long-term light source illumination, making it ideal for everyday lighting.

In view of the above problems, a main object of the present invention is to provide a method for producing a solid-state light-emitting body, which is formed into a solid-state light-emitting body by a potting method by mixing a light-emitting powder with an inorganic powder or an organic powder. The molding is easy and does not damage the structure and luminescence characteristics of the luminescent powder itself. The solid illuminator has excellent high temperature resistance, can effectively prevent high temperature cracking caused by long-term illumination of the illuminating element, and can improve the service life and reliability. .

Another object of the present invention is to provide a method for manufacturing a solid-state light-emitting body, which can be carried out under normal temperature or low temperature environment, and has a simple preparation process, does not require high energy consumption, and can reduce equipment and process costs.

In order to achieve the above object, the present invention provides a method for producing a solid-state light-emitting body, which comprises the steps of uniformly mixing a luminescent powder and an inorganic powder to form a mixed raw material, which is 100% by weight based on the total weight of the mixed raw material, and a luminescent powder. The content is from 3 to 20% by weight, the content of the inorganic powder is from 50 to 97% by weight, and the luminescent powder is a phosphor powder, a phosphor powder or a mixture thereof, and the inorganic powder contains calcium sulfate and calcium oxide or cerium oxide. Subsequently, the mixed raw materials are uniformly mixed with the solvent to form a mixed liquid. Then, the mixed liquid is poured into the mold to be solidified into a solid-state light-emitting body, and the solid-state light-emitting body generates visible light by being excited by the light source of the light-emitting element.

The invention also provides a method for manufacturing another solid-state light-emitting body, which comprises the steps of: uniformly mixing the luminescent powder with the organic powder to form a mixed raw material, the content of the luminescent powder is 100% by weight based on the total weight of the mixed raw material, 3 to 20% by weight, the content of the organic powder is 50 to 97% by weight, and the luminescent powder is a fluorescent powder, a phosphor powder or a mixture thereof, and the organic powder is a ruthenium rubber or an epoxy rubber. Then, the mixed raw materials are uniformly mixed with the solvent to form a mixed liquid. The mixture is poured into a mold and solidified into a solid state light emitter.

In short, according to the method for producing a solid-state light-emitting body according to the present invention, the luminescent powder may be mixed with an inorganic powder or an organic powder, and then mixed as a mixed solution by adding a solvent. A fill is provided in the mold and then cured to form a solid state light emitter. The invention has simple process and simple equipment, wherein each step of mixing, infusion and solidification can be operated under normal temperature or low temperature conditions, in addition to low energy consumption and cost saving, and at the same time, the luminescent powder itself is not damaged. The structural characteristics provide a suitable wavelength of light and a good luminous efficiency. Therefore, the solid state light-emitting body produced by the invention has excellent luminescent properties and high temperature resistance, and can be widely applied to daily illumination for long-term use.

The purpose, technical content, features and effects achieved by the present invention will be more readily understood by the detailed description of the embodiments.

In order to clearly disclose the technical features of the manufacturing method of the solid-state light-emitting body disclosed in the present invention, the specific embodiments will be described below to explain the technical features of the present invention in detail, and the technical features are also shown in the drawings.

Please refer to FIG. 1 , which is a flow chart of a method for manufacturing a solid state light emitting body according to a first embodiment of the present invention. The various steps are described in detail below.

First, referring to step S01, the luminescent powder and the inorganic powder are uniformly mixed to form a mixed raw material. The composition ratio of the mixed raw materials is 100% by weight based on the total weight of the mixed raw materials, wherein the content of the luminescent powder is 3 to 20% by weight, and the content of the inorganic powder is 50 to 97% by weight, further, in the mixed raw material Up to 30% by weight of glass frit can be added. The composition of the luminescent powder may be derived from phosphor powder or phosphor powder of various illuminating colors; for example, the phosphor powder may be yellow fluorescing powder, green fluorescing powder or red fluorescing powder, which is not limited thereto. Of course, the luminescent powder can also be formed by mixing the phosphor powder and the phosphor powder in a certain ratio. The inorganic powder component may comprise calcium sulfate and calcium oxide or cerium oxide, and the total weight of the inorganic powder is 100% by weight, the calcium sulfate content is 80 to 97% by weight, and the content of calcium oxide or cerium oxide is It is 3 to 20 weight percent.

Then, referring to step S02, a solvent is added to the mixed raw materials, and uniformly mixed to form a mixed liquid. In this embodiment, the volume ratio of the mixed raw material to the solvent is from 40:50 to 50:50, and the solvent is specifically water. In the mixing process of the mixed solution, the mixed solution may be further subjected to ball milling for 2 to 4 hours at a temperature of 10 to 40 ° C to uniformly disperse the mixed raw material in the mixed solution.

Thereafter, as shown in Fig. 2, as shown in Fig. 2, the mixed liquid 10 is poured into the mold 20 at normal temperature (RT), and is solidified and molded to obtain the final product of the solid state light body 30. The material of the mold 20 can be plastic, ceramic or metal. Further, the step of solidifying molding may be carried out naturally at a normal temperature for 24 hours at a mold 20 in which the mixed solution 10 is poured, or may be subjected to a low-temperature slow drying at a temperature of 50 ° C for 8 hours.

Finally, the mold is again released. As shown in FIG. 3A or FIG. 3B, the solid state light emitter 30 can be used to generate visible light by being excited by a light source of a light-emitting element 40. The light-emitting element 40 can be a blue laser, a violet laser, a red laser, a green laser or a yellow laser.

In addition, the solid state light emitting body prepared by the invention may be transparent, translucent or opaque, depending on the composition ratio of the mixed raw materials, and can be applied to various lighting devices according to the transparent or opaque characteristics. To achieve the effect of light source penetration or reflection (see Figures 3A and 3B, respectively), for example, if it is an opaque solid state light emitter, it can be applied to the reflective layer of the lighting device.

The solid state light emitter obtained in the above embodiment is based on an inorganic powder, and may also be an organic powder as a substrate. Please refer to FIG. 4, which is a flow chart of a method for manufacturing a solid state light emitting body according to a second embodiment of the present invention. The various steps are described in detail below.

First, referring to step S11, the luminescent powder and the organic powder are uniformly mixed to form a mixed raw material. The composition ratio of the mixed raw materials is 100% by weight based on the total weight of the mixed raw materials, wherein the content of the luminescent powder is 3 to 20% by weight, and the content of the organic powder is 50 to 97% by weight, further, in the mixed raw material Up to 30% by weight of glass frit can be added. The composition of the luminescent powder may be derived from phosphor powder or phosphor powder of various illuminating colors; for example, the phosphor powder may be yellow fluorescing powder, green fluorescing powder or red fluorescing powder, which is not limited thereto. Of course, the luminescent powder can also be formed by mixing the phosphor powder and the phosphor powder in a certain ratio. The composition of the organic powder may comprise ruthenium rubber or epoxy glue.

Then, referring to step S12, a solvent is added to the mixed raw materials, and uniformly mixed to form a mixed liquid. In this embodiment, the volume ratio of the mixed raw material to the solvent is from 40:50 to 50:50, and the solvent is specifically a degreased oil or methyl ethyl ketone. In the mixing process of the mixed solution, the mixed solution may be further subjected to ball milling for 4 to 6 hours at a temperature of 10 to 40 ° C to uniformly disperse the mixed raw material in the mixed solution.

Thereafter, as seen in step S13, as shown in Fig. 2, the mixed liquid 10 is poured into the mold 20 at room temperature (RT), and is solidified and molded to obtain the final product of the solid state light body 30. The material of the mold 20 can be plastic, ceramic or metal. In addition, the step of solidifying molding can be carried out for a mold 20 in which the mixed liquid 10 is poured, at a temperature of 50 ° C for 1 hour at a low temperature, and then at a temperature of 150 ° C for 1 hour. .

Finally, the mold release 30, as shown in FIG. 3A or FIG. 3B, can be used to generate visible light by being excited by a light source of a light-emitting element 40. The light-emitting element 40 can be a blue laser, a violet laser, a red laser, a green laser or a yellow laser.

Similarly, the solid state light emitter prepared by the invention can be transparent, translucent or opaque, depending on the composition ratio of the mixed raw materials, and can be applied to various lighting devices according to the transparent or opaque characteristics. For the purpose of light source penetration or reflection, for example, if it is an opaque solid state light emitter, it can be applied to the reflective layer of the illumination device and achieve the purpose of performing photoluminescence wavelength conversion.

Different from the conventional technology, the solid state light emitter is formed by high temperature calcination, so that the lattice structure of the phosphor powder is easily damaged, and the light emitting property is changed. The present invention is a phosphor powder, a phosphor powder, and a glass. The powder is mixed with an inorganic powder or an organic powder to form a mixed liquid, so that it can be formed into an inorganic or organic solid illuminant by a perfusion method under normal temperature or low temperature conditions.

Therefore, according to the method for manufacturing a solid-state light-emitting body disclosed by the present invention, since a complicated and high-energy high-temperature process is not required, not only the process is easy, but also a simple and inexpensive low-energy-consuming device can be utilized, thereby achieving an effect of saving production cost.

At the same time, according to the method for manufacturing a solid-state light-emitting body disclosed in the present invention, since it can be carried out under relatively low temperature conditions, it is not easy to damage the lattice structure of the luminescent powder material itself, and does not affect its luminescent property, but can provide appropriate The illuminating wavelength and the better illuminating efficiency, thereby contributing to the improvement of the high temperature resistance and illuminating ability of the solid illuminant.

Therefore, the manufacturing method according to the present invention can provide a solid state light emitting body with excellent high temperature resistance and light emitting performance, which can effectively prevent the long-term illumination of the light-emitting element, in addition to the object of simplicity, convenience, and low cost. High temperature cracking will significantly increase its reliability and service life. Therefore, the present invention can be widely applied to various daily illuminations for long-term use, and can make transparent, semi-transparent or reflective solid-state illuminators, such as a reflective layer of a lighting device, etc., according to different requirements, thereby achieving better efficiency. And achieve lower costs to improve industrial competitiveness.

The above is only the preferred embodiment of the present invention and is not intended to limit the scope of the present invention. Therefore, any changes or modifications of the features and spirits of the present invention should be included in the scope of the present invention.

10‧‧‧ mixture

20‧‧‧Mold

30‧‧‧Solid illuminators

40‧‧‧Lighting elements

Fig. 1 is a flow chart showing a method of manufacturing a solid state light emitter according to a first embodiment of the present invention. Fig. 2 is a schematic view showing a pouring forming step in the method for producing a solid state light emitting body provided by the present invention. 3A and 3B are schematic views showing the use of the transmissive and reflective solid-state illuminators produced by the present invention, respectively. Figure 4 is a flow chart showing a method of manufacturing a solid state light emitter according to a second embodiment of the present invention.

Claims (17)

A method of manufacturing a solid-state light-emitting system that generates visible light by excitation of a light source of a light-emitting element, the method comprising the steps of: providing a mixed raw material comprising at least one luminescent powder and an inorganic powder The luminescent powder is contained in an amount of 3 to 20% by weight based on the total weight of the mixed raw material, the inorganic powder is 50 to 97% by weight, and the luminescent powder is phosphor powder or phosphorescent. a powder or a mixture thereof, the inorganic powder comprising calcium sulfate and calcium oxide or cerium oxide; the mixed raw material is uniformly mixed with a solvent to form a mixed liquid, and the volume ratio of the mixed raw material to the solvent is 40:50 to 50:50, and the solvent is water; and the mixture is poured into a mold and then solidified into the solid state light emitter. The method of producing a solid state light emitter according to claim 1, wherein the mixed raw material further comprises up to 30% by weight of glass frit. The method of producing a solid state light emitter according to claim 1, wherein the inorganic powder comprises 80 to 97 weight percent of calcium sulfate and 3 to 20 weight percent based on 100% by weight of the total weight of the inorganic powder. Calcium oxide or cerium oxide. The method for producing a solid state light emitter according to claim 1, wherein the phosphor powder is at least one selected from the group consisting of yellow phosphor powder, green phosphor powder, and red phosphor powder. The method for producing a solid state light emitter according to claim 1, wherein after the mixture is formed, ball milling is carried out at a temperature of 10 to 40 ° C for 2 to 4 hours. The method for producing a solid-state light-emitting body according to claim 1, wherein the step of solidifying molding is performed on the mold infused with the mixed liquid at a temperature of from ordinary temperature to 50 ° C for 8 to 24 hours. Dry or dry. The method of manufacturing a solid state light emitter according to claim 1, wherein the mold is made of plastic, ceramic or metal. The method of manufacturing a solid state light emitter according to claim 1, wherein the light emitting element is a blue laser, a violet laser, a red laser, a green laser or a yellow laser. The method of producing a solid state light emitter according to claim 1, wherein the solid state light emitter is transparent, translucent or opaque. A method for manufacturing a solid-state light-emitting system, wherein the solid-state light-emitting system generates visible light by excitation of a light source of a light-emitting element, the manufacturing method comprising the steps of: providing a mixed raw material comprising at least one light-emitting powder and one organic powder The luminescent powder is contained in an amount of 3 to 20% by weight based on the total weight of the mixed raw material, the organic powder is 50 to 97% by weight, and the luminescent powder is phosphor powder or phosphorescent. a powder or a mixture thereof, the organic powder is a ruthenium rubber or an epoxy glue; the mixed raw material is uniformly mixed with a solvent to form a mixed liquid, and the volume ratio of the mixed raw material to the solvent is 40:50 to 50:50. And the solvent is a degreased oil or methyl ethyl ketone; and the mixture is poured into a mold and then solidified into the solid illuminant. The method of producing a solid state light emitter according to claim 10, wherein the mixed raw material further comprises up to 30% by weight of glass frit. The method of producing a solid state light emitter according to claim 10, wherein the phosphor powder is at least one selected from the group consisting of yellow phosphor powder, green phosphor powder, and red phosphor powder. The method for producing a solid state light emitter according to claim 10, wherein after the mixture is formed, ball milling is carried out for 4 to 6 hours at a temperature of 10 to 40 °C. The method for producing a solid-state light-emitting body according to claim 10, wherein the step of solidifying molding is performed by drying the mold filled with the mixed liquid at a temperature of 50 ° C for 1 hour, and then Curing was carried out for 1 hour at a temperature of 150 °C. The method of manufacturing a solid state light emitter according to claim 10, wherein the mold is made of plastic, ceramic or metal. The method of manufacturing a solid state light emitter according to claim 10, wherein the light emitting element is a blue laser, a violet laser, a red laser, a green laser or a yellow laser. The method of producing a solid state light emitter according to claim 10, wherein the solid state light emitter is transparent, translucent or opaque.