PREPARATION OF HIGH EMISSION EFFICIENCY ALKALINE EARTH METAL THIOGALLATE PHOSPHORS
This application claims priority from Provisional
application Serial No. 60/222,678 filed August 2, 2000.
This invention relates to a method of preparing high emission efficiency thiogallate phosphors. More particularly,
this invention relates to a method of preparing high emission
efficiency alkaline earth metal thiogallate phosphors activated with europium.
BACKGROUND OF THE INVENTION
Alkaline earth metal thiogallate phosphors (MGa2S4) activated with divalent europium, praseodymium, trivalent
cerium and mixtures thereof, have been disclosed by Peters et al, J. Electrochem. Soc . , Vol. 119, 1972, p230. These
phosphors were made by solid state reaction from the alkaline
earth sulfide, gallium sulfide and rare earth sulfides. They
emit in the green to yellow region of the spectrum. They have
good saturation properties, but their emission efficiency is low, at about 30% that of other sulfide phosphors. However,
high efficiency phosphors are required for field emission displays, projection television, and blue-violet diode laser
light sources.
Thus a method of preparing the above phosphors that
results in an improvement of their emission efficiency would
be highly desirable.
SUMMARY OF THE INVENTION
We have found that activated alkaline earth metal
thiogallate phosphors having improved emission efficiency can
be made by intimately mixing their insoluble sulfate salt
precursors having a small particle size with gallium nitrate
solution, in amounts to produce a small excess of gallium. The
soluble salts are precipitated with sulfuric acid or ammonium
sulfate to form their corresponding insoluble sulfates. These
solids are then fired in hydrogen sulfide to form the
corresponding thiogallate sulfide phosphors.
DETAILED DESCRIPTION OF THE INVENTION
The present method includes the following steps.
A soluble alkali metal salt, as of strontium or calcium
nitrate, is dissolved in dilute nitric acid. The desired
amount of europium activator (1-6 mol percent) is added as a
soluble salt, such as its nitrate. Neutralization with
ammonium hydroxide produces a suspension of alkali metal
sulfate particles coated with europium hydroxide.
The following equation summarizes this step:
Sr(S04) + Eu(N03)2 + NH4OH - SrS04 • Eu(OH)3 + NH4OH
Sulfuric acid or ammonium sulfate is added to precipitate
the corresponding insoluble alkali metal sulfate. The particle size of the resultant precipitate should be kept small. This
can be done by controlling the temperature and concentration
of the soluble salt solution and by diluting the solution with
an organic, miscible solvent, such as an alcohol.
A solution of an acid-soluble gallium salt, such as the
nitrate, is also made. This can be done by dissolving the
metal in nitric acid overnight. Since gallium oxide is very
difficult to convert to an oxide-free sulfide with hydrogen sulfide, the oxide starting material is not recommended.
The gallium nitrate is added to the europium hydroxide
coated alkaline earth sulfate in sufficient amount so as to
produce an excess of from about 0.1-7 percent by weight of
gallium sulfide in the final gallium sulfide product, as
Sr(S04) :Eu:2.01Ga(OH)3
After combining these solutions and bringing the mixture
to a neutral pH with ammonia, or by carrying out a
precipitation of gallium using urea, a solid precipitates. The solid phosphor precursor is dried, ground, placed in a refractory boat, such as an alumina boat, and fired in hydrogen sulfide for about five hours in a tube furnace.
Suitably the firing temperature is about 800°C. The sulfide
product obtained is shown below:
SrGa2S4:Eu:Ga2S4
To ensure uniformity of the product, the sulfide material
is ground to a powder and refired in hydrogen sulfide at 900°C for about two hours. The resultant strontium thiogallate phosphor has a particle size of about 8-10 microns. Its
emission efficiency was measured at 80-100 percent.
The resultant green emitting, high emission efficiency
phosphor should show a slight excess of gallium sulfide by means of x-ray analysis, in the range of about 0.5-7 %.
If an organic solvent, such as an alcohol or acetone is
added when the sulfate is precipitated, and firing is carried
out at a lower temperature, such as 780°C for five hours and 850°C for about four hours, the average particle size of the
product will be somewhat smaller, e.g., about 5-6 microns.
Thus the product particle size can be controlled as required
by the final use of the phosphor.
A like calcium gallium sulfide activated with Eu can be made in similar manner but substituting a calcium salt for the strontium salt. A mixed crystal phosphor of strontium and calcium can also be made. Cerium or praseodymium can be
substituted, in whole or in part, for the europium activator.
Reducing the amount of gallium present (for example a 5
to 3% excess) reduces the particle size and sometimes the
relative efficiency of the SrGa2S4 phosphor.
For example, samples with a 5% excess gallium, fired at
900°C for two hours can have a relative efficiency range of
from about 66 to 100%, with a median particle size of about
8.59 to 9.41 microns.
A sample with 3% excess gallium, plus the addition of alcohol in the precipitation step and fired at 850°C for four
hours, can have a relative efficiency of about 82% and a
median particle size of about 3.63 microns.
The invention will be further described by means of the
following examples. However, the invention is not meant to be
limited to the details described therein.
In the Examples, all parts are by weight.
Example 1
A solution of gallium nitrate was prepared as follows:
57.45 parts of gallium were dissolved in 400 ml cone, nitric acid. The mixture was heated until brown fumes appeared, when
the heat was removed and the container covered. After standing
overnight, the resultant green solution was alternately heated
and cooled until it turned yellow, and then clear. Deionized
water was added to form 1000 ml of solution.
Ammonium hydroxide (about 80 ml) was added slowly to
obtain a solution pH of about 2. Water was added to make up 1200 ml of the solution.
Europium oxide (2.815 parts) was solubilized in 400 ml of
dilute nitric acid. Strontium carbonate was added slowly,
adding more nitric acid if needed. 1.2 ml of a 0.01 M solution
of praseodymium oxide was also added, and water was added to
make up 600 ml of solution.
Ammonium sulfate (120 parts) was dissolved in 540 ml of
water to make up 600 ml of solution.
The ammonium sulfate solution was added with stirring to the strontium-europium-praseodymium nitrate solution. The
mixture was stirred for ten minutes, and acidified to a pH of
about 1.4. The gallium nitrate solution was added, and the pH
raised to 7 with ammonium hydroxide. The mixture was stirred
for two hours and allowed to stand overnight.
The supernatant solution was decanted and filtered and
the precipitate washed with acetone. The precipitate was re-
suspended in 2500 ml of acetone, stirring for 1 hour at 50°C, and then filtered. The re-suspension step was repeated, and
the precipitate dried overnight at 55°C.
The precipitate was ground in a ball mill with 140 alumina balls %"x7/l6" in size in acetone and dried overnight.
182 Grams of material were obtained.
The ground precipitate was heated at a rate of 20°C/min to
800°C in hydrogen sulfide and held for five hours. The resulting green phosphor was re-ground and fired again, this
time at 900°C in hydrogen sulfide for two hours. The average
particle size was about 8-10 microns. A yield of 120 grams was
obtained.
The green-emitting phosphor had a relative efficiency of 100%. Example 2
57.45 Parts of gallium was warmed until it liquified and
was dissolved in 400 parts by volume of nitric acid. When
brown fumes were seen, it was removed from the heat, covered and let set overnight. A green solution was obtained which was
warmed and cooled until it turned yellow, and finally clear.
Deionized water was added to make a one liter solution.
Ammonium hydroxide (about 80 ml) was added to a pH of about 2, and water added to make up 1200 ml of solution.
Europium oxide was dissolved in 400 ml of dilute nitric
acid. Strontium carbonate was added slowly, and then 1.2 ml of
0.01M praseodymium solution was added. Water was added to make
up 600 ml of solution. The pH should be about 0.02 to 0.2 and
was adjusted as required.
500 Ml of ethanol was added slowly.
50 Ml of sulfuric acid was diluted with 300 ml of deionized water. The dilute sulfuric acid was added to the
strontium-europium-praeseodymium solution and stirred for 10
minutes. The pH was adjusted as required to be about the same
as the gallium solution. The gallium solution was added. The pH was adjusted to 7, and ethyl alcohol was added to make up 3.5 liters. The mixture was stirred for two hours, let set overnight and filtered. The precipitate was washed with
acetone . The precipitate was re-suspended in 3500 ml of acetone by
stirring for one hour at 50°C. The solids were filtered and
dried overnight at 55°C.
The solids were then ground and ball milled in 2500 ml of
acetone including 140 alumina balls. The solids were filtered
and dried overnight at 55°.
The precipitate was fired at 780°C for five hours, and then at 850°C for four hours. The average particle size was
smaller than that of Example 1, i.e., about 5-6 microns. Thus
the phosphor was somewhat less efficient, about 82%, but had a
smaller median particle size of about 4 microns.
Although the invention has been described in terms of
particular embodiments, one skilled in the art will well know how to change the ingredients and their relative amounts. Thus
the invention is only meant to be limited to the details
described in the following claims.