WO2010058290A2 - Lanthanide compounds - Google Patents

Lanthanide compounds Download PDF

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Publication number
WO2010058290A2
WO2010058290A2 PCT/IB2009/007599 IB2009007599W WO2010058290A2 WO 2010058290 A2 WO2010058290 A2 WO 2010058290A2 IB 2009007599 W IB2009007599 W IB 2009007599W WO 2010058290 A2 WO2010058290 A2 WO 2010058290A2
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metal
group
compound
compound according
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PCT/IB2009/007599
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WO2010058290A3 (en
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Wen Tian Fu
Jan Reedijk
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Universiteit Leiden
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    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00Luminescent, e.g. electroluminescent, chemiluminescent materials
    • C09K11/08Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials
    • C09K11/77Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials containing rare earth metals
    • C09K11/7766Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials containing rare earth metals containing two or more rare earth metals
    • C09K11/7774Aluminates
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00Luminescent, e.g. electroluminescent, chemiluminescent materials
    • C09K11/08Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials
    • C09K11/77Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials containing rare earth metals
    • C09K11/7715Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials containing rare earth metals containing cerium
    • C09K11/7721Aluminates

Definitions

  • the present invention relates to the provision of novel lanthanide compounds and their use as phosphor materials, especially, but not exclusively, in ultraviolet activated light-emitting diodes.
  • LEDs Light emitting diodes
  • SSL solid-state lighting
  • LEDs have higher energy conversion efficiency. It is estimated that the ultimate performance of LEDs might reach 200 lm/W.
  • LEDs have very long lifetime (>100000 h) , which can effectively reduce the maintenance costs.
  • LEDs are solid-state devices and are therefore not susceptible to vibration and can withstand far more abuse than glass- based lamps.
  • LEDs are regarded as environmentally friendly since they do not contain dangerous metals such as mercury or lead.
  • white LEDs are required.
  • One way to create white LEDs is the so-called multi-chip solution, which combines three LEDs emitting in the blue, green and red regions of the visible spectrum respectively.
  • This solution presents some difficulties.
  • Current green/yellow LEDs have very poor efficiency in comparison with available blue or red LEDs.
  • wavelengths of the emission spectra of compositions used in current green/yellow emitting compositions are not situated at suitable or required wavelengths to combine with the red and blue emitters to provide a bright white light.
  • the three LED components used in multi chip devices have different voltage requirements, different degradation characteristics and different temperature dependencies, sophisticated control systems are required.
  • An alternative solution is to use a single LED chip combined with appropriate compositions, which exhibit suitable phosphorescence (phosphors) .
  • Two alternatives have been suggested: combining a blue emitting LED with suitable phosphor (s) or combining an ultraviolet emitting LED with three suitable phosphors .
  • red phosphor e.g. CaS: Eu 2+
  • This can give a lamp with a color temperature of about 3200 K and a CRI value exceeding 90.
  • the efficiency of such devices drops, however, to about 2/3 due mainly to unfavorable spectral distribution of the red phosphor.
  • the alternative approach uses a UV emitting LED (e.g. emitting at a wavelength of 380 nm) to excite three phosphors (red green, blue) , similar to those used in tricolor fluorescent lamps. Since the three colors are generated simultaneously, a high lumen output as well as a high CRI can be realized.
  • UV LEDs when compared to the blue LED approach, UV LEDs have an additional quantum deficit (loss of efficiency of energy transfer) of about 15%. Accordingly, the UV LED approach is only suitable if this extra energy loss is sufficiently compensated by a high lumen equivalent from the phosphors employed in the device .
  • Rare earth phosphors especially Tb 3+ and Eu 3+ - dopped materials, emit line spectra in the visible region, so that a high "light output", i.e. high lumen equivalent, is produced. This helps to compensate for the additional quantum deficit of the color conversion.
  • the present invention provides a compound, according to general formula 1:
  • M(II) represents a divalent metal selected from the group of Ca, Sr and mixtures thereof
  • Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof
  • M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof
  • p and q represent fractional numbers varying between 0 and 1, and l ⁇ p+q>0.
  • the compounds of the invention contain cerium (Ce 3+ ) and/or terbium (Tb 3+ ) .
  • Ce 3+ cerium
  • Tb 3+ terbium
  • p + q >0.1.
  • the trivalent metal M' (III) of formula 1 may be substituted to some extent by a tetravalent component M''' (IV) .
  • the ratio of M''' (IV) component to M' (III) in a compound may be at up to 1:1.
  • the tetravalent component M''' (IV) may be selected from Si(IV), Ge(IV) and mixtures thereof.
  • the additional + charge provided by the M''' (IV) component may be balanced by further substitution of the trivalent metal M' (III) with a divalent metal M'' (II).
  • the charge balance of the compound may be maintained by the substitution of the divalent metal M(II) of formula 1 with a monovalent metal M'''' (I) .
  • the charge balance of the compound may be maintained by substitution in formula 1 with both divalent metal M'' (II) and monovalent metal M'''' (I) in selected amounts sufficient to maintain charge balance of the compound.
  • the divalent metal M'' (II) may be selected from the group consisting of Zn(II), Mg(II) and mixtures thereof.
  • the monovalent metal M''' (I) may be selected from the group consisting of K, Na and mixtures thereof.
  • the compounds of the invention may take the form of formula 2 :
  • M(II), Ln(III), M' (III), p and q have the same meaning as before;
  • M''' (IV) is a tetravalent component selected from the group consisting of Si(IV), Ge (IV) and mixtures thereof;
  • M'' (II) is a divalent metal; and
  • r is a fractional number having the value l ⁇ r>0.
  • the compounds of the invention may take the form of formula 3 :
  • M(II), Ln(III), M' (III), p and q have the same meaning as before;
  • M''' (IV) is a tetravalent component selected from the group consisting of Si(IV), Ge (IV) and mixtures thereof;
  • M'''' (I) is a monovalent metal; and
  • r is a fractional number having the value l>r>0.
  • Preferred compounds of the invention may have the structure of the mineral melilite as discussed with reference to specific examples below.
  • Preferred compounds of formula 1 include but are not limited to: CaYi- p Ce p Al 3 ⁇ 7 , CaYi- q Tb q Al 3 0 7 and CaY 1-p-q Ce p Tb q Al 3 ⁇ 7 . More preferred compounds of formula 1 include but are not limited to:
  • Compounds according to the invention have been found to emit light in the blue (with Ce 3+ containing or Ce 3+ doped compounds) green (Tb 3+ containing or Tb 3+ doped compounds) or in both the green and blue parts of the visible spectrum (compounds containing both Ce 3+ and Tb 3+ ) when excited by an appropriate UV light. These emissions make compounds according to the invention suitable for use as phosphors in lighting applications.
  • M(II) represents a divalent metal selected from the group of Ca, Sr or mixtures thereof
  • Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof
  • M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof
  • p and q represent fractional numbers varying between 0 and 1 and l ⁇ p+q>0; as a phosphor.
  • the trivalent metal M' (III) of the composition of formula 1 may be substituted by a tetravalent component M'' (IV), with appropriate adjustments to the composition to balance the charges.
  • the strong optical absorption bands of the allowed Ce 3+ 4f-5d transitions in known oxide compositions are usually observed in the far UV, at less than about 320 nm.
  • the green phosphor (Ce, Tb, Gd) MgB5O10 absorbs only to about 10% at 380 nm (T. J ⁇ stel, H. Nikol, C. Ronda, Angew. Chem. Int. Ed. 37 (1998) 3084) .
  • Compounds of the present invention comprising both Ce 3+ and Tb 3+ can provide such new phosphor materials wherein the Tb 3+ -emission is sensitized by Ce 3+ -ions, and the latter ions are capable of absorbing the near-UV light close to 380 nm.
  • the phosphor materials described can emit two different colors simultaneously and are therefore ideally suited as both blue and green light providers in lighting applications.
  • the compounds of the invention have a melilite structure or a structure related to melilite, it is believed that the compounds of the present invention provide these advantages by virtue of their crystal structure as discussed in more detail below.
  • Such a structure creates a strong crystal field around the Ce 3+ ions displacing the Ce 3+ 4f-5d absorption bands towards the near-UV region.
  • the distance between the lanthanide ions in the structure is not too large, facilitating effective energy transfer between Ce 3+ and Tb 3+ ions .
  • Phosphor materials of the invention that contain both Ce 3+ and Tb 3+ therefore have two emission centers, thus they can emit different colors (blue and green) .
  • the relative concentrations of the activator components, i.e. Ce 3+ and Tb 3+ can be adjusted at the atomic level simply by adjusting the amount of each cation present in a mixture used to form the compound.
  • a desired output color, for between blue and green, can readily be obtained more precisely than by mixing two separate phosphor compounds.
  • the compounds of the invention containing both Ce 3+ and Tb 3+ can be considered as "two prime color phosphors" .
  • the luminescent compounds of the invention containing Ce 3+ exhibit high levels of absorption when subject to near-UV light, exceeding 95% at 380 nm. They also show intense emissions with a high quantum efficiency. Combined with their excellent stability these properties make them ideal candidates for lighting devices especially near-UV LED- based lighting devices.
  • the present invention provides a light comprising a compound according to general formula 1: M(Il)Ln(lIl) x _ p _ q Ce(III) 9 Tb(111) q M'(JIJ) 3 O 7 (1) wherein M(II) represents a divalent metal selected from the group of Ca, Sr or mixtures thereof; Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof; M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof; and wherein p and q represent fractional numbers varying between 0 and 1 and l ⁇ p+q>0; as a phosphor.
  • M(II) represents a divalent metal selected from the group of Ca, Sr or mixtures thereof
  • Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof
  • M' (III) is another trivalent metal
  • the light further comprises a UV LED as exciter for the phosphor.
  • a UV LED as exciter for the phosphor.
  • Other types of light making use of an emitter in the near-UV region to excite the phosphor may make use of the compounds of the invention.
  • the compounds of the present invention may be manufactured by intimately mixing (preferably by grinding) appropriate metal carbonates and/or metal oxides and then sintering the resultant mixture in a reducing atmosphere or under vacuum conditions.
  • a reducing atmosphere it may be, for example, a hydrogen-containing atmosphere, as described hereafter with reference to specific embodiments.
  • Other precursor compounds containing the chosen metals that will thermally decompose under appropriate conditions to the metal oxides as required may be employed. For example, nitrates oxalates and other organic salts.
  • the present invention provides a method for the preparation of a compound according to general formula 1 :
  • M(II) represents a divalent metal selected from the group of Ca, Sr or mixtures thereof
  • Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof
  • M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof; and wherein p and q represent fractional numbers varying between 0 and 1 and l ⁇ p+q>0; as a phosphor;
  • metal oxides, or metal compounds decomposable under the reaction conditions to give metal oxide in calculated proportions to give a mixture having the desired relative compositions of the metal ions, M(II), M' (III), Ln(III), Ce(III) and Tb(III); and sintering the mixture under a reducing atmosphere, or under vacuum conditions, to produce the compound of general formula 1.
  • An appropriate flux material such as are well known in the art may be added to the mixture to assist forming the compound.
  • the reducing atmosphere is a hydrogen-containing atmosphere.
  • a carbon monoxide (CO) atmosphere may be employed.
  • the sintering is carried out at a temperature in excess of 1000 0 C, more preferably in excess of 1300 0 C.
  • a hydrogen containing reducing atmosphere is not suitable when Ga, Ge or Zn oxides are present in the mixtures, as they will tend to be reduced directly to their metals under these conditions .
  • the compounds of the invention may be prepared by other means such as are well known in the art, for example by co- precipitation or sol-gel techniques. Brief description of the Drawings
  • Fig. 1 is a schematic drawing of the crystal structure of CaLnAl 3 O 7 ; and Figs. 2 and 3 show emission and excitation spectra of compounds of the invention.
  • a compound corresponding to the formula CaY o.8 oCe o.2 oAl 3 O 7 was prepared from the following mixture:
  • the powders were intimately mixed by grinding together.
  • the resulting mixture was placed in an alumina or a platinum crucible, and sintered at 1450 °C in a diluted hydrogen flow for 15 hours .
  • the product is a white crystalline powder, which is insensitive to added water. It shows an intense blue emission when irradiated by 365 nm UV radiation.
  • a compound corresponding to the formula CaCe 0-75 Tb 0.25 Al 3 O 7 was prepared from the following mixture:
  • the powders were intimately mixed by grinding together.
  • the resulting mixture was placed in an alumina or a platinum crucible, and sintered at 1450 0 C in a diluted hydrogen flow for 15 hours .
  • the product obtained is a white crystalline powder, which is insensitive to water. It shows an intense green emission when irradiated by 365 nm UV radiation.
  • the compound has the melilite-type structure.
  • the structure consists of layers of edge-shared (Ca, Ln) O 8 polyhedra, which are separated by the layers of corner-linked AlO 4 tetrahedra.
  • the geometry of the (Ca 1 Ln)O 8 polyhedra is a deformed square antiprism. Such an anion arrangement is expected to create a strong crystal field around the large lanthanide cations.
  • the shortest distance, in the case of aluminates, between cations (Ca/Ln) is about 4.1 A. Such a short distance between adjacent cations favors energy transfer between Ce 3+ and Tb 3+ ions when they are introduced into the structure.
  • FIG. 2 shows the excitation and emission spectra of CaY 0 . 8 Ce 0 .2Al 3 O 7 .
  • the emission due to the presence of the Ce3 + -ions is blue with the emission maximum at about 435 nm.
  • the excitation spectrum of Ce 3+ consists of two broad bands with the strongest between approximately 310 nm and 400 nm (i.e. near UV light).
  • the figure demonstrates that Ca (Y, Ce) Al 3 O 7 compounds of the melilite-type can absorb near-UV light efficiently and are suitable for use as the blue prime phosphor in a UV-LED light.
  • doped only with Tb 3+ these compounds cannot be excited efficiently using near-UV light as the first excitation band corresponding to the Tb 3+ 4f-5d transitions is centered at shorter wavelength, about 275 nm. Therefore such a compound has more limited utility in lighting applications.
  • the excitation spectrum of Tb 3+ has additional bands in the near UV similar to those observed in the excitation spectrum of Ca (Y, Ce)Al 3 O 7 shown in figure 2.

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Abstract

A compound, according to general formula 1: M( II )Ln(III) 1-p-q Ce(III) p Tb(III) q M'(III) 3 O 7 wherein M(II) represents a divalent metal selected from the group of Ca, Sr and mixtures thereof; Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof; M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof; and wherein p and q represent fractional numbers varying between 0 and 1, and1≥p+q>0 is provided. M' (III) may be substituted by a tetravalent component M''' (IV), in which case the trivalent metal M' (III) may be substituted with a divalent metal M'' (II) or the divalent metal M(II) may be substituted with a monovalent metal M'''' (I) to maintain charge balance. The compounds of formula 1 can find use as phosphors including in lighting applications.

Description

Lanthanide Compounds
Field of the invention
The present invention relates to the provision of novel lanthanide compounds and their use as phosphor materials, especially, but not exclusively, in ultraviolet activated light-emitting diodes.
Background of the Invention
Light emitting diodes (LEDs) are expected to provide the next generation of illuminating light sources. When compared to the conventional incandescent or fluorescent light sources, this so-called solid-state lighting (SSL) offers many advantages. For example, LEDs have higher energy conversion efficiency. It is estimated that the ultimate performance of LEDs might reach 200 lm/W. In addition, LEDs have very long lifetime (>100000 h) , which can effectively reduce the maintenance costs. Further, LEDs are solid-state devices and are therefore not susceptible to vibration and can withstand far more abuse than glass- based lamps. Finally, LEDs are regarded as environmentally friendly since they do not contain dangerous metals such as mercury or lead.
For general lighting purposes, "white LEDs" are required. One way to create white LEDs is the so-called multi-chip solution, which combines three LEDs emitting in the blue, green and red regions of the visible spectrum respectively. This solution, however, presents some difficulties. Current green/yellow LEDs have very poor efficiency in comparison with available blue or red LEDs. In addition, wavelengths of the emission spectra of compositions used in current green/yellow emitting compositions are not situated at suitable or required wavelengths to combine with the red and blue emitters to provide a bright white light. Furthermore because the three LED components used in multi chip devices have different voltage requirements, different degradation characteristics and different temperature dependencies, sophisticated control systems are required.
An alternative solution is to use a single LED chip combined with appropriate compositions, which exhibit suitable phosphorescence (phosphors) . Two alternatives have been suggested: combining a blue emitting LED with suitable phosphor (s) or combining an ultraviolet emitting LED with three suitable phosphors .
The first option was proposed and demonstrated by S. Nakamura (MRS Bulletin 22 (1997) 29) , and has been commercialized since then. This approach uses a blue LED, emitting at about 460 nm, and a single phosphor Y3Al5Oi2: Ce (YAG: Ce) . Part of the blue light is converted by the phosphor to a yellow light, which is the complimentary color of blue, thus producing white light. An advantage of this method is the high conversion efficiency, due to relatively low quantum deficit during the conversion of blue to yellow light. However, this particular combination only provides lamps with a high color temperature, >4000 K, resulting in a relatively poor color rendering index (CRI) (-75) .
Some improvements have been made by introducing an additional red phosphor, e.g. CaS: Eu2+ to the compositions employed. This can give a lamp with a color temperature of about 3200 K and a CRI value exceeding 90. The efficiency of such devices drops, however, to about 2/3 due mainly to unfavorable spectral distribution of the red phosphor. The alternative approach uses a UV emitting LED (e.g. emitting at a wavelength of 380 nm) to excite three phosphors (red green, blue) , similar to those used in tricolor fluorescent lamps. Since the three colors are generated simultaneously, a high lumen output as well as a high CRI can be realized. However, when compared to the blue LED approach, UV LEDs have an additional quantum deficit (loss of efficiency of energy transfer) of about 15%. Accordingly, the UV LED approach is only suitable if this extra energy loss is sufficiently compensated by a high lumen equivalent from the phosphors employed in the device .
Lanthanide-activated phosphors have been successively applied in tricolor fluorescent lamps for more than three decades. Rare earth phosphors, especially Tb3+ and Eu3+- dopped materials, emit line spectra in the visible region, so that a high "light output", i.e. high lumen equivalent, is produced. This helps to compensate for the additional quantum deficit of the color conversion.
However, not all phosphors currently used in mercury discharge lamps absorb UV light efficiently in the wavelength range close to 380 nm, i.e. the output range of a typical UV LED. This is particularly the case for Tb3+- activated (green) phosphors, although some Eu3+-activated phosphors that do absorb satisfactorily at 380 nm with high quantum efficiencies are known (Y2O2SrEu3+ and Y (V, P, B) O4: Eu3+, for example) .
It is the object of the present invention to provide phosphor materials for use in lighting applications that can avoid or at least mitigate at least one of the aforementioned problems. Summary of the Invention
According to a first aspect the present invention provides a compound, according to general formula 1:
M(JI)LΩ(JIJ)1_p_ςrCe(JJl)pTJb(JJI)gM'(JJJ)3O7 (1)
wherein M(II) represents a divalent metal selected from the group of Ca, Sr and mixtures thereof; Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof; M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof; and wherein p and q represent fractional numbers varying between 0 and 1, and l≥p+q>0.
The compounds of the invention contain cerium (Ce3+) and/or terbium (Tb3+) . Preferably p + q >0.1.
The trivalent metal M' (III) of formula 1 may be substituted to some extent by a tetravalent component M''' (IV) . The ratio of M''' (IV) component to M' (III) in a compound may be at up to 1:1. The tetravalent component M''' (IV) may be selected from Si(IV), Ge(IV) and mixtures thereof.
In order to maintain the necessary charge balance in the compound, the additional + charge provided by the M''' (IV) component, over that provided by M' (III), may be balanced by further substitution of the trivalent metal M' (III) with a divalent metal M'' (II). Alternatively the charge balance of the compound may be maintained by the substitution of the divalent metal M(II) of formula 1 with a monovalent metal M'''' (I) . As a yet further alternative the charge balance of the compound may be maintained by substitution in formula 1 with both divalent metal M'' (II) and monovalent metal M'''' (I) in selected amounts sufficient to maintain charge balance of the compound. The divalent metal M'' (II) may be selected from the group consisting of Zn(II), Mg(II) and mixtures thereof. The monovalent metal M'''' (I) may be selected from the group consisting of K, Na and mixtures thereof.
For example, where the charge balance is achieved by replacing M' (III) with a divalent metal M'' (II) the compounds of the invention may take the form of formula 2 :
M(II)Ln(ffl)1_p_qCe(in)pTb(in)qM'(in)3_2rM"(n)rM'"(IV)rO7 (2)
wherein M(II), Ln(III), M' (III), p and q have the same meaning as before; M''' (IV) is a tetravalent component selected from the group consisting of Si(IV), Ge (IV) and mixtures thereof; M'' (II) is a divalent metal; and r is a fractional number having the value l≥r>0.
For example, where the charge balance is achieved by replacing M(II) with a monovalent metal M'''' (I) the compounds of the invention may take the form of formula 3 :
M(II)l_rM""(l)rLn(lIl)l_p_gCe(III)pTb(lII)qM'(lIl)^rM'"(lV)rO1 (3)
wherein M(II), Ln(III), M' (III), p and q have the same meaning as before; M''' (IV) is a tetravalent component selected from the group consisting of Si(IV), Ge (IV) and mixtures thereof; M'''' (I) is a monovalent metal; and r is a fractional number having the value l>r>0.
Preferred compounds of the invention may have the structure of the mineral melilite as discussed with reference to specific examples below.
Preferred compounds of formula 1 include but are not limited to: CaYi-pCepAl3θ7, CaYi-qTbqAl307 and CaY1-p-qCepTbqAl3θ7. More preferred compounds of formula 1 include but are not limited to:
CaY0.8Ce0.2Al3O7 , CaY0.8Tb0.2A13O7 , CaY0.7Ce0.15Tb0.15Al3O7 , CaCe0.75Tb0.25Al3O7 and CaCeAl3O7.
Compounds according to the invention have been found to emit light in the blue (with Ce3+ containing or Ce3+ doped compounds) green (Tb3+ containing or Tb3+ doped compounds) or in both the green and blue parts of the visible spectrum (compounds containing both Ce3+ and Tb3+) when excited by an appropriate UV light. These emissions make compounds according to the invention suitable for use as phosphors in lighting applications.
Thus according to a second aspect the present invention provides the use of a compound according to general formula 1:
M{ll)Ln{III)λ_p_qCe{iτi)pTb{Hl)qW(IIJ)3O7 ( 1 ) wherein M(II) represents a divalent metal selected from the group of Ca, Sr or mixtures thereof; Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof; M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof; and wherein p and q represent fractional numbers varying between 0 and 1 and l≥p+q>0; as a phosphor.
As described above the trivalent metal M' (III) of the composition of formula 1 may be substituted by a tetravalent component M'' (IV), with appropriate adjustments to the composition to balance the charges.
Combining both Ce3+ and Tb3+ in the same compound presents some additional advantages, especially in regard to obtaining efficient emission of green light. According to quantum selection rules, for Tb3+ intra 4f-4f transitions are both spin and parity forbidden. Furthermore the allowed Tb3+ transitions (4f-5d) are of a much higher energy. Therefore the efficient population of the light emitting 4f excited state for Tb3+ can only be achieved, through use of an appropriate sensitizer. The Ce3+ ion is known to be an excellent sensitizer for Tb3+. For example the use of Ce3+ as sensitizer has been successfully applied to the green phosphors used in current mercury discharge lamps.
However, the strong optical absorption bands of the allowed Ce3+ 4f-5d transitions in known oxide compositions are usually observed in the far UV, at less than about 320 nm. For example, the green phosphor (Ce, Tb, Gd) MgB5O10 absorbs only to about 10% at 380 nm (T. Jύstel, H. Nikol, C. Ronda, Angew. Chem. Int. Ed. 37 (1998) 3084) .
To be able to use Tb3+ 5D4-7Fj (J=2-6) transitions as the green primary color in a UV-LED based lamp (where the UV emission is around 380 nm) , one needs to displace the Ce3+ 4f-5d absorption bands towards the near-UV region while still maintaining the efficient energy transfer from Ce3+ to Tb3+.
Compounds of the present invention comprising both Ce3+ and Tb3+ can provide such new phosphor materials wherein the Tb3+-emission is sensitized by Ce3+-ions, and the latter ions are capable of absorbing the near-UV light close to 380 nm. In addition, the phosphor materials described can emit two different colors simultaneously and are therefore ideally suited as both blue and green light providers in lighting applications.
Where the compounds of the invention have a melilite structure or a structure related to melilite, it is believed that the compounds of the present invention provide these advantages by virtue of their crystal structure as discussed in more detail below. Such a structure creates a strong crystal field around the Ce3+ ions displacing the Ce3+ 4f-5d absorption bands towards the near-UV region. At the same time the distance between the lanthanide ions in the structure is not too large, facilitating effective energy transfer between Ce3+ and Tb3+ ions .
Phosphor materials of the invention that contain both Ce3+ and Tb3+ therefore have two emission centers, thus they can emit different colors (blue and green) . The relative concentrations of the activator components, i.e. Ce3+ and Tb3+, can be adjusted at the atomic level simply by adjusting the amount of each cation present in a mixture used to form the compound. A desired output color, for between blue and green, can readily be obtained more precisely than by mixing two separate phosphor compounds. In this respect, the compounds of the invention containing both Ce3+ and Tb3+ can be considered as "two prime color phosphors" .
The luminescent compounds of the invention containing Ce3+ exhibit high levels of absorption when subject to near-UV light, exceeding 95% at 380 nm. They also show intense emissions with a high quantum efficiency. Combined with their excellent stability these properties make them ideal candidates for lighting devices especially near-UV LED- based lighting devices. According to a third aspect the present invention provides a light comprising a compound according to general formula 1: M(Il)Ln(lIl)x_p_qCe(III)9Tb(111)qM'(JIJ)3O7 (1) wherein M(II) represents a divalent metal selected from the group of Ca, Sr or mixtures thereof; Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof; M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof; and wherein p and q represent fractional numbers varying between 0 and 1 and l≥p+q>0; as a phosphor.
Preferably the light further comprises a UV LED as exciter for the phosphor. Other types of light making use of an emitter in the near-UV region to excite the phosphor may make use of the compounds of the invention.
The compounds of the present invention may be manufactured by intimately mixing (preferably by grinding) appropriate metal carbonates and/or metal oxides and then sintering the resultant mixture in a reducing atmosphere or under vacuum conditions. Where a reducing atmosphere is employed it may be, for example, a hydrogen-containing atmosphere, as described hereafter with reference to specific embodiments. Other precursor compounds containing the chosen metals that will thermally decompose under appropriate conditions to the metal oxides as required may be employed. For example, nitrates oxalates and other organic salts.
Thus according to a fourth aspect the present invention provides a method for the preparation of a compound according to general formula 1 :
M(ll)Ln(lIl)λ_p_qCe(lIl)pTb(Hl)q M'(HI)3O7 ( 1 ) wherein M(II) represents a divalent metal selected from the group of Ca, Sr or mixtures thereof; Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof; M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof; and wherein p and q represent fractional numbers varying between 0 and 1 and l≥p+q>0; as a phosphor;
the method comprising:
intimately mixing together metal oxides, or metal compounds decomposable under the reaction conditions to give metal oxide in calculated proportions to give a mixture having the desired relative compositions of the metal ions, M(II), M' (III), Ln(III), Ce(III) and Tb(III); and sintering the mixture under a reducing atmosphere, or under vacuum conditions, to produce the compound of general formula 1.
An appropriate flux material such as are well known in the art may be added to the mixture to assist forming the compound.
Preferably, when used, the reducing atmosphere is a hydrogen-containing atmosphere. Alternatively a carbon monoxide (CO) atmosphere may be employed. Preferably the sintering is carried out at a temperature in excess of 1000 0C, more preferably in excess of 1300 0C. A hydrogen containing reducing atmosphere is not suitable when Ga, Ge or Zn oxides are present in the mixtures, as they will tend to be reduced directly to their metals under these conditions .
The compounds of the invention may be prepared by other means such as are well known in the art, for example by co- precipitation or sol-gel techniques. Brief description of the Drawings
Fig. 1 is a schematic drawing of the crystal structure of CaLnAl3O7; and Figs. 2 and 3 show emission and excitation spectra of compounds of the invention.
Description of the Invention with reference to the preparation of compounds of the invention and results of tests
The following examples illustrate the preparation and the characteristics of the phosphor compounds of the invention.
Example 1
A compound corresponding to the formula CaYo.8oCeo.2oAl3 O7 was prepared from the following mixture:
Starting Quantity materials ( g)
CaCO3 3 . 013
Y2O3 2 . 719
CeO2 1 . 036
Al2O3 4 . 604
The powders were intimately mixed by grinding together. The resulting mixture was placed in an alumina or a platinum crucible, and sintered at 1450 °C in a diluted hydrogen flow for 15 hours .
The product is a white crystalline powder, which is insensitive to added water. It shows an intense blue emission when irradiated by 365 nm UV radiation. Example 2
A compound corresponding to the formula CaCe0-75Tb0.25Al3 O7 was prepared from the following mixture:
Starting Quantity materials (g)
CaCO3 2 . 649
CeO2 3 . 416
Tb4O7 1 . 236
Al2O3 4 . 047
The powders were intimately mixed by grinding together. The resulting mixture was placed in an alumina or a platinum crucible, and sintered at 1450 0C in a diluted hydrogen flow for 15 hours .
The product obtained is a white crystalline powder, which is insensitive to water. It shows an intense green emission when irradiated by 365 nm UV radiation.
Structural characterization
All compounds prepared using the method described above were found to be crystalline powders. X-ray diffraction study shows that they all have the melilite structure having tetragonal symmetry with the space group P42,m . Structural refinement, using the Rietveld method, was carried out on two representative compounds and the refined results are listed below:
CaCeAl3O7
Table 1. Refined lattice constants, atomic positions and thermal parameters of CaCeAl3O7 in the space group P42,m . CaCeAl3O7
~a 7.79190(7) A c 5.13908(6) A
x y z B(A)2
Ca/Ce 4e 0.1607(1) 0.6607(1) 0.5071 (3) 0.81(2)
Al(I) 2a 0 0 0 0.75( (9)
Al(2) 4e 0.3560(3) 0.8560(3) 0.9611(6) 0.42(6)
0(1) 2c 0 0.5 0.1704(17) 0.22(10)
0(2) 4e 0.3547(7) 0.8547(7) 0.2897(10) 0.85(15)
0(3) Sf 0.3446(6) 0.4139(5) 0.1899(7) 0.07(6)
Rwp=13.61%, Rp=IO.00%, χ2=2.31
CaCe0.75Tb0-2SAl3O7
Table 2. Refined lattice constants, atomic positions and thermal parameters of CaCe0.75Tb0.25Al3O7 in the space group
P42,m .
CaCe0.75Tb0.25Al3O7 ~a 7.77142(9) A
C 5.11829(8) A
x y z B(A)2
Ca/Ce/Tb 4e 0.1603(1) 0.6603(1) 0.5095 (3) 0.94(2)
Al(I) 2a 0 0 0 0.65( (1O)
Al(2) 4e 0.3555(3) 0.8555(3) 0.9632(8) 0.74(7)
0(1) 2c 0 0.5 0.1685(21) 1.02(28)
0(2) 4e 0.3549(8) 0.8549(8) 0.2875(12) 1.04(17)
0(3) 8f 0.3447(6) 0.4130(6) 0.1901(9) 0.48(12)
Rwp=14.89%, Rp=IO.92%, χ2=2.14 A schematic drawing of the structure of the undoped (i.e. not containing Ce3+ or Tb3+) compound CaLnAl3O7 is shown in Figure 1 to demonstrate the structure of the compounds of the invention.
The compound has the melilite-type structure. As shown in figure 1, the structure consists of layers of edge-shared (Ca, Ln) O8 polyhedra, which are separated by the layers of corner-linked AlO4 tetrahedra. The geometry of the (Ca1Ln)O8 polyhedra is a deformed square antiprism. Such an anion arrangement is expected to create a strong crystal field around the large lanthanide cations. In addition, the shortest distance, in the case of aluminates, between cations (Ca/Ln) is about 4.1 A. Such a short distance between adjacent cations favors energy transfer between Ce3+ and Tb3+ ions when they are introduced into the structure.
The luminescent properties of Ce3+-doped CaYAl3O7 are shown in Fig. 2. Figure 2 shows the excitation and emission spectra of CaY0.8Ce0.2Al3O7.
The emission due to the presence of the Ce3+-ions is blue with the emission maximum at about 435 nm. The excitation spectrum of Ce3+ consists of two broad bands with the strongest between approximately 310 nm and 400 nm (i.e. near UV light). The figure demonstrates that Ca (Y, Ce) Al3O7 compounds of the melilite-type can absorb near-UV light efficiently and are suitable for use as the blue prime phosphor in a UV-LED light.
The Tb3+ emission in Tb3+-doped CaYAl3O7 is green consisting of several sharp emission lines corresponding to the transitions between the 5D4 and the multiple 7Fj (J=2-6) energy levels as shown in Figure 3 (right hand spectrum - CaY0.8Tb0.2Al3O7 spectrum shown) . However, if doped only with Tb3+ these compounds cannot be excited efficiently using near-UV light as the first excitation band corresponding to the Tb3+ 4f-5d transitions is centered at shorter wavelength, about 275 nm. Therefore such a compound has more limited utility in lighting applications.
However when the compounds of the invention are co-doped with Ce3+, e.g. Ca (Y, Ce, Tb) Al3O7 compounds, the excitation spectrum of Tb3+ has additional bands in the near UV similar to those observed in the excitation spectrum of Ca (Y, Ce)Al3O7 shown in figure 2.
In particular, there is a strong excitation band centered at about 356 nm as shown in the excitation spectrum for CaY0.7Ce0.15Tb0.15Al3O7 of figure 3 (left hand spectrum) . This allows Tb3+ containing compounds, when co-doped with Ce3+, to emit green light efficiently when excited by near-UV light (at around 380 nm) .
The energy transfer from Ce3+ to Tb3+ in the Ca (Y, Ce, Tb) Al3O7 system was found to be incomplete, as a residual Ce3+- emission is observed in the emission spectrum upon excitation with light of λ=380 nm. The intensity of these residual Ce3+ emissions depends on the relative amounts of Ce and Tb. Phosphor materials with a low Ce and Tb concentration, e.g. CaY0-7Ce0.15Tb0.15Al3O7, show a bright whitish emission under a high-pressure mercury discharge lamp (λ=365 nm) . On the other hand the emission color of the phosphors in a compound with a relatively high Ce and Tb concentration, e.g. CaCe0-75Tb0.25Al3O7, is essentially green.
The above experiments demonstrate that the Ce3+ and Tb3+ containing compounds contain two emission centers, thus emitting different colors (Fig. 2 and Fig. 3) . The amount of each color emitted can be adjusted as desired by altering the level of Ce3+ and Tb3+ doping applied.

Claims

1. A compound, according to general formula 1:
M(Il)Lπ(JIl),_p_gCe(JIJ)pTb(JII)gM'(JJJ)3θ7 (1) wherein M(II) represents a divalent metal selected from the group, constituting of Ca, Sr and mixtures thereof ;
Ln(III) is a trivalent metal selected from the group consisting of Y, Gd, La, Lu and mixtures thereof; M' (III) is another trivalent metal selected from the group consisting of Al, Ga and mixtures thereof; and p and q represent fractional numbers varying between 0 and 1, and l≥p+q>0; and, optionally, wherein: the trivalent metal M' (III) is substituted by a tetravalent component M''' (IV) selected from the group consisting of Si(IV), Ge(IV) and mixtures thereof, the ratio of the tetravalent M''' (IV) component to the trivalent metal M' (III) being at up to 1:1; and, to maintain the charge balance : the trivalent metal M' (III) is further substituted with a divalent metal M'' (II); or the divalent metal M(II) is substituted with a monovalent metal M'''' (I); or both the trivalent metal M' (III) and the divalent metal M(II) are substituted with selected amounts of divalent metal M'' (II) and monovalent metal M'''' (I) respectively, sufficient to maintain charge balance of the compound.
2. A compound according to claim 1 wherein p + q >0.1.
3. A compound according to claim 1 or claim 2 containing both Ce and Tb.
4. A compound according to any one of claims 1 to 3 wherein the divalent metal M'' (II) is present and is selected from the group consisting of Zn(II), Mg(II) and mixtures thereof .
5. A compound according to any one of claims 1 to 3 wherein the monovalent metal M'''' (I) is present and is selected from the group consisting of K, Na and mixtures thereof .
6. A compound according to any one of claims 1 to 4 wherein the compound is of formula 2 : M(II)Ln(III)1.^Ce(III)pTb(III)qM'(III)3_2rM"(II)rM-(IV)rO7 (2)
wherein M(II), Ln(III), M' (III), M'" (IV), M" (II), p and q have the same meaning as before; and r is a fractional number having the value l≥r>0.
7. A compound according to any one of claims 1 to 3 and 5 wherein the compound is of formula 3 : Af(ll)l-rM""(J)rMJI-O1_p_gCe(JIΪ)pTHlIϊ)qM'(IIJ)3_rM'"(JV)rO7 (3 )
wherein M(II), Ln(III), M' (III), M''' (IV), M'''' (I), P and q have the same meaning as before; and r is a fractional number having the value l≥r>0.
8. A compound according to any one of the preceding claims wherein the compound has the melilite structure.
9. A compound according to claim 1 selected from the group consisting of:
CaYi-pCepAl3θ7, CaYi-qTbqAl307 and CaYi-p.qCepTbqAlaOv .
10. A compound according to claim 9 selected from the group consisting of:
CaY0.8Ce0.2Al3O7 , CaY0.8Tb0.2Al3O7 , CaY0.7Ce0.15Tb0.15Al3O7 , CaCe0.-75Tb0.25A13O7 and CaCeAl3O7.
11. The use of a compound according to any one of claims 1 to 10 as a phosphor.
12. A light comprising a compound according to any one of claims 1 to 10 as a phosphor.
13. A light according to claim 12 further comprising a UV LED as exciter for the phosphor.
14. A method for the preparation of a compound according to any one of claims 1 to 10 the method comprising: intimately mixing together metal oxides, or metal compounds decomposable under the reaction conditions to give metal oxide in calculated proportions to give a mixture having the desired relative compositions of the metal ions, ; and sintering the mixture under a reducing atmosphere or under vacuum conditions to produce the compound.
15. A method according to claim 14 wherein a hydrogen- containing reducing atmosphere, or a CO-containing reducing atmosphere, is employed and the sintering is carried out at a temperature in excess of 10000C.
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