WO2017192322A1 - Phosphor materials for light sources and method for fluidizing the same - Google Patents

Phosphor materials for light sources and method for fluidizing the same Download PDF

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Publication number
WO2017192322A1
WO2017192322A1 PCT/US2017/029534 US2017029534W WO2017192322A1 WO 2017192322 A1 WO2017192322 A1 WO 2017192322A1 US 2017029534 W US2017029534 W US 2017029534W WO 2017192322 A1 WO2017192322 A1 WO 2017192322A1
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WIPO (PCT)
Prior art keywords
phosphor
pfs
potassium hexafluorosilicate
blend
fluidization
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Ceased
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PCT/US2017/029534
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French (fr)
Inventor
William Winder Beers
Fangming Du
Clark David NELSON
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Current Lighting Solutions LLC
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GE Lighting Solutions LLC
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Filing date
Publication date
Application filed by GE Lighting Solutions LLC filed Critical GE Lighting Solutions LLC
Priority to MYPI2018703719A priority Critical patent/MY186678A/en
Priority to JP2018557420A priority patent/JP7244277B2/en
Priority to CN202510062592.8A priority patent/CN119875627A/en
Priority to KR1020187034565A priority patent/KR102379088B1/en
Priority to CN201780027462.4A priority patent/CN109072074A/en
Priority to MX2018013328A priority patent/MX2018013328A/en
Priority to CA3021557A priority patent/CA3021557C/en
Priority to DE112017002296.7T priority patent/DE112017002296T5/en
Publication of WO2017192322A1 publication Critical patent/WO2017192322A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00—Luminescent materials, e.g. electroluminescent or chemiluminescent
    • C09K11/08—Luminescent materials, e.g. electroluminescent or chemiluminescent containing inorganic luminescent materials
    • C09K11/61—Luminescent materials, e.g. electroluminescent or chemiluminescent containing inorganic luminescent materials containing fluorine, chlorine, bromine, iodine or unspecified halogen elements
    • C09K11/617—Silicates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/08—Metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
    • C09D183/04—Polysiloxanes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/22—Luminous paints
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/80—Processes for incorporating ingredients
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K11/00—Luminescent materials, e.g. electroluminescent or chemiluminescent
    • C09K11/02—Use of particular materials as binders, particle coatings or suspension media therefor
    • C09K11/025—Use of particular materials as binders, particle coatings or suspension media therefor non-luminescent particle coatings or suspension media
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00—Electroluminescent light sources
    • H05B33/12—Light sources with substantially two-dimensional [2D] radiating surfaces
    • H05B33/14—Light sources with substantially two-dimensional [2D] radiating surfaces characterised by the chemical or physical composition or the arrangement of the electroluminescent material, or by the simultaneous addition of the electroluminescent material in or onto the light source
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00—Electroluminescent light sources
    • H05B33/12—Light sources with substantially two-dimensional [2D] radiating surfaces
    • H05B33/20—Light sources with substantially two-dimensional [2D] radiating surfaces characterised by the chemical or physical composition or the arrangement of the material in which the electroluminescent material is embedded
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/851—Wavelength conversion means
    • H10H20/8511—Wavelength conversion means characterised by their material, e.g. binder
    • H10H20/8512—Wavelength conversion materials
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/80—Constructional details
    • H10H20/85—Packages
    • H10H20/852—Encapsulations
    • H10H20/854—Encapsulations characterised by their material, e.g. epoxy or silicone resins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C08K2003/2227—Oxides; Hydroxides of metals of aluminium
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/01—Manufacture or treatment
    • H10H20/036—Manufacture or treatment of packages
    • H10H20/0361—Manufacture or treatment of packages of wavelength conversion means
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10H—INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
    • H10H20/00—Individual inorganic light-emitting semiconductor devices having potential barriers, e.g. light-emitting diodes [LED]
    • H10H20/01—Manufacture or treatment
    • H10H20/036—Manufacture or treatment of packages
    • H10H20/0362—Manufacture or treatment of packages of encapsulations

Definitions

  • Some light sources include phosphor bodies disposed on or near the light sources.
  • These phosphor bodies, or phosphors receive at least some of the light generated by the light sources.
  • the received light causes the phosphors to emit light.
  • some light emitting diodes include red-emitting phosphors that receive light generated by the LEDs to emit light.
  • a potassium hexafluorosilicate (PFS)-based material can be blended with silicone. This blended mixture is then placed onto the LED and allowed to cure to form the phosphor.
  • PFS-based material may be in a powder form that is mixed with the silicone. During the mixing of the PFS-based powder into the silicone, the powder may aggregate into larger clumps. Electrostatic forces can cause this aggregation of the PFS-based powder.
  • the clumps of the PFS-based powder can reduce the amount of the PFS material that receives light from the light source, as only the outer surface area of the larger clumps may receive the light while the interior of the clumps may not receive the light.
  • the amount of light received by the PFS material to generate light emitted from the phosphor that includes the PFS material is decreased (relative to a phosphor having no clumps or smaller aggregations of the PFS material).
  • the PFS and silicone blend may be dispensed through a nozzle or other device having a relatively small opening.
  • the clumps or other aggregations of the PFS material in the blend may clog or otherwise impede flow of the blend through and out of the nozzle onto the LED, thereby interfering with formation of the phosphors. Additionally, the larger clumps of the PFS-based powder can reduce the ability of the phosphor to dissipate heat (relative to a phosphor having no clumps or smaller clumps) and reduce the useful life span of the phosphor.
  • a method includes obtaining a potassium hexafluorosilicate
  • PFS-based powder obtaining a fluidization material, and mixing the PFS-based powder with the fluidization material to form a PFS-based mixture.
  • the PFS-based mixture is configured to be mixed with a resinous material to form a flowing phosphor blend configured to be placed onto a light source to form a phosphor on the light source.
  • a method in another embodiment, includes obtaining a potassium hexafluorosilicate (PFS)-based powder, obtaining a metal oxide fluidization material, and mixing the PFS-based powder with the metal oxide fluidization material to form a PFS-based mixture.
  • the PFS-based mixture is configured to be mixed with a resinous material to form a phosphor blend that is configured to form a phosphor of a light source.
  • a phosphor body is provided that is formed from a potassium hexafluorosilicate (PFS)-based powder, a metal oxide fluidization material, and a resinous material.
  • PFS potassium hexafluorosilicate
  • Figure 1 illustrates a flowchart of one embodiment of a method for fluidizing phosphor materials and optionally for creating phosphors using fluidized phosphor materials
  • Figure 2 illustrates mixing of a PFS-based material with a fluidization material to form a fluidized PFS-based mixture according to one embodiment
  • Figure 3 illustrates mixing of the fluidized PFS-based mixture shown in Figure 2 with a resinous material according to one embodiment
  • Figure 4 illustrates placing a phosphor blend shown in Figure 3 onto a light source according to one embodiment
  • Figure 5 illustrates loose densities of the PFS-based mixture shown in Figure 2 and internal quantum yields or quantum efficiencies (QY) of the PFS-based mixture for different weight percentages of fluidization material in the PFS-based mixture.
  • FIG. 1 illustrates a flowchart of one embodiment of a method 100 for fluidizing phosphor materials and optionally for creating phosphors using fluidized phosphor materials.
  • a PFS-based powder is obtained.
  • the PFS-based powder can be potassium hexafluorosilicate that is doped with tetravalent manganese (Mn 4+ ).
  • Mn 4+ tetravalent manganese
  • another type of phosphor material may be obtained.
  • the PFS-based material may be in the form of a powder when the PFS-based material is obtained by disintegrating a larger solid body of the PFS-based material, such as by grinding or crushing the larger solid body.
  • the PFS-based material may be in the form of a powder when the PFS-based material has an average or median of the largest outside non-circumferential dimension or diameter that is no greater than one tenth of a millimeter.
  • the fluidization material includes a metal oxide powder in one embodiment.
  • the fluidization material may include aluminum oxide.
  • the fluidization material may include another metal oxide powder or a material such as silica or fumed silica.
  • the fluidization material may be provided in a powder when the particles of the fluidization material have a very small size, such as an average or median of the largest outside non-circumferential dimension or diameter that is smaller than one micron.
  • the fluidization material is mixed with the PFS-based powder to form a
  • Figure 2 illustrates mixing of a PFS-based material 200 with a fluidization material 202 to form a fluidized PFS-based mixture 204 according to one embodiment.
  • the amount of the fluidization material 202 that is mixed into the PFS-based material 200 may be relatively small.
  • the total weight of the fluidization material 202 that is mixed with the PFS-based material 200 may be no more than 0.1% of the weight of the PFS-based material 200.
  • the total weight of the fluidization material 202 that is mixed with the PFS- based material 200 may be no more than 0.08%, no more than 0.06%, no more than 0.05%, no more than 0.04%, no more than 0.03%, or no more than 0.02% of the weight of the PFS-based material 200.
  • the method 100 optionally includes mixing the fluidized PFS-based mixture 204 with a resinous material at 108.
  • Figure 3 illustrates mixing of the fluidized PFS-based mixture 204 shown in Figure 2 with a resinous material 300 according to one embodiment.
  • the fluidized mixture 204 and the resinous material 300 are combined to form a flowing phosphor blend 302.
  • the blend 302 may flow by being at least partially fluid until the blend 302 cures into a solid body.
  • the resinous material 300 is silicone, such as polydimethylsiloxane. Alternatively, another curable resinous material may be used.
  • the method 100 optionally includes placing the phosphor blend onto a light source at 110.
  • Figure 4 illustrates placing the phosphor blend 302 onto a light source 400 according to one embodiment.
  • the phosphor blend 302 may be injected onto the light source 400, such as a semiconductor-based light source (e.g., an LED), by injecting the blend 302 from a reservoir 402 through a nozzle 404 and onto the light source 400.
  • the blend 302 may be sprayed or otherwise dispensed from the nozzle 404.
  • the blend 302 may at least partially encapsulate the light source 400.
  • the blend 302 may then be cured to harden on or over the light source 400.
  • the cured blend 302 forms the phosphor or phosphor body on the light source 400 that emits light responsive to receiving light generated by the light source 400.
  • the nozzle 404 may have a relatively small outlet or orifice through which the blend 302 exits the nozzle 404.
  • the outlet may have a diameter of 70 microns or smaller.
  • particles of the PFS-based material 200 in the blend 302 may clog the outlet of the nozzle 404 and prevent additional blend 302 from being dispensed from the nozzle 404. Addition of the fluidization material 202 to the PFS-based material 200 prevents this clogging from occurring.
  • FIG. 5 illustrates loose densities 500 of the PFS-based material 200 in the PFS-based mixture 204 and internal quantum yields or quantum efficiencies (QY) 502 of the PFS-based mixture 204 for different weight percentages of fluidization material 202 in the mixture 204.
  • the internal quantum yields or efficiencies may represent a ratio of the number of photons exiting a sample of the PFS-based mixture to the number of photons that are absorbed by the sample.
  • the internal quantum yields or efficiencies may be measured by the FS5 spectrofluorometer with integrating sphere produced by Edinburgh Instruments.
  • the PFS-based material 200 is potassium hexafluorosilicate doped with tetravalent manganese and the fluidization material 202 is aluminum oxide.
  • the loose densities 500 and the quantum yields 502 are shown alongside a horizontal axis 504 representative of different weight percentages of the aluminum oxide in the mixture 204 and alongside a first vertical axis 506 representative of different loose densities and alongside a second vertical axis 508 representative of different internal quantum yields or efficiencies.
  • addition of the fluidization material 202 to the PFS-based material 200 increases the loose density 500 of the PFS-based material 200 even at relatively low amounts (e.g., at 0.005% weight percentage).
  • amount of the fluidization material 202 added to the PFS-based mixture 204 increases (e.g., amounts of 0.03% to 0.07% weight percentage)
  • the loose density 500 becomes constant or substantially constant and is about 20% greater than the loose density 500 with no fluidization material 202 added to the PFS-based material 200.
  • the quantum efficiency 502 of the PFS-based mixture 204 over this range is, within measurement error of powders, is constant or substantially constant.

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Abstract

A method includes obtaining a potassium hexafluorosilicate (PFS)-based powder, obtaining a fluidization material, and mixing the PFS-based powder with the fluidization material to form a PFS-based mixture. The PFS-based mixture is configured to be mixed with a resinous material to form a flowing phosphor blend configured to be placed onto a light source to form a phosphor on the light source.

Description

PHOSPHOR MATERIALS FOR LIGHT SOURCES AND METHOD FOR
FLUIDIZING THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 62/330,401, which was filed on 02-May-2016, and the entire disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] Some light sources include phosphor bodies disposed on or near the light sources.
These phosphor bodies, or phosphors, receive at least some of the light generated by the light sources. The received light causes the phosphors to emit light. For example, some light emitting diodes (LEDs) include red-emitting phosphors that receive light generated by the LEDs to emit light.
[0003] In order to create the phosphors, a potassium hexafluorosilicate (PFS)-based material can be blended with silicone. This blended mixture is then placed onto the LED and allowed to cure to form the phosphor. One problem that may arise in the blending of the PFS- based material with the silicone is the aggregation of the PFS-based material into larger clumps. For example, the PFS-based material may be in a powder form that is mixed with the silicone. During the mixing of the PFS-based powder into the silicone, the powder may aggregate into larger clumps. Electrostatic forces can cause this aggregation of the PFS-based powder.
[0004] These clumps can cause problems with the phosphors and forming the phosphors.
The clumps of the PFS-based powder can reduce the amount of the PFS material that receives light from the light source, as only the outer surface area of the larger clumps may receive the light while the interior of the clumps may not receive the light. As a result, the amount of light received by the PFS material to generate light emitted from the phosphor that includes the PFS material is decreased (relative to a phosphor having no clumps or smaller aggregations of the PFS material). During formation of the phosphors, the PFS and silicone blend may be dispensed through a nozzle or other device having a relatively small opening. The clumps or other aggregations of the PFS material in the blend may clog or otherwise impede flow of the blend through and out of the nozzle onto the LED, thereby interfering with formation of the phosphors. Additionally, the larger clumps of the PFS-based powder can reduce the ability of the phosphor to dissipate heat (relative to a phosphor having no clumps or smaller clumps) and reduce the useful life span of the phosphor.
BRIEF DESCRIPTION
[0005] In one embodiment, a method includes obtaining a potassium hexafluorosilicate
(PFS)-based powder, obtaining a fluidization material, and mixing the PFS-based powder with the fluidization material to form a PFS-based mixture. The PFS-based mixture is configured to be mixed with a resinous material to form a flowing phosphor blend configured to be placed onto a light source to form a phosphor on the light source.
[0006] In another embodiment, a method includes obtaining a potassium hexafluorosilicate (PFS)-based powder, obtaining a metal oxide fluidization material, and mixing the PFS-based powder with the metal oxide fluidization material to form a PFS-based mixture. The PFS-based mixture is configured to be mixed with a resinous material to form a phosphor blend that is configured to form a phosphor of a light source.
[0007] In one embodiment, a phosphor body is provided that is formed from a potassium hexafluorosilicate (PFS)-based powder, a metal oxide fluidization material, and a resinous material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The subject matter described herein will be better understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:
[0009] Figure 1 illustrates a flowchart of one embodiment of a method for fluidizing phosphor materials and optionally for creating phosphors using fluidized phosphor materials;
[0010] Figure 2 illustrates mixing of a PFS-based material with a fluidization material to form a fluidized PFS-based mixture according to one embodiment;
[0011] Figure 3 illustrates mixing of the fluidized PFS-based mixture shown in Figure 2 with a resinous material according to one embodiment;
[0012] Figure 4 illustrates placing a phosphor blend shown in Figure 3 onto a light source according to one embodiment; and [0013] Figure 5 illustrates loose densities of the PFS-based mixture shown in Figure 2 and internal quantum yields or quantum efficiencies (QY) of the PFS-based mixture for different weight percentages of fluidization material in the PFS-based mixture.
DETAILED DESCRIPTION
[0014] Figure 1 illustrates a flowchart of one embodiment of a method 100 for fluidizing phosphor materials and optionally for creating phosphors using fluidized phosphor materials. At 102, a PFS-based powder is obtained. The PFS-based powder can be potassium hexafluorosilicate that is doped with tetravalent manganese (Mn4+). Alternatively, another type of phosphor material may be obtained. The PFS-based material may be in the form of a powder when the PFS-based material is obtained by disintegrating a larger solid body of the PFS-based material, such as by grinding or crushing the larger solid body. In one embodiment, the PFS-based material may be in the form of a powder when the PFS-based material has an average or median of the largest outside non-circumferential dimension or diameter that is no greater than one tenth of a millimeter.
[0015] At 104, a fluidization material is obtained. The fluidization material includes a metal oxide powder in one embodiment. For example, the fluidization material may include aluminum oxide. Alternatively, the fluidization material may include another metal oxide powder or a material such as silica or fumed silica. The fluidization material may be provided in a powder when the particles of the fluidization material have a very small size, such as an average or median of the largest outside non-circumferential dimension or diameter that is smaller than one micron.
[0016] At 106, the fluidization material is mixed with the PFS-based powder to form a
PFS-based mixture. Figure 2 illustrates mixing of a PFS-based material 200 with a fluidization material 202 to form a fluidized PFS-based mixture 204 according to one embodiment. The amount of the fluidization material 202 that is mixed into the PFS-based material 200 may be relatively small. For example, the total weight of the fluidization material 202 that is mixed with the PFS-based material 200 may be no more than 0.1% of the weight of the PFS-based material 200. Alternatively, the total weight of the fluidization material 202 that is mixed with the PFS- based material 200 may be no more than 0.08%, no more than 0.06%, no more than 0.05%, no more than 0.04%, no more than 0.03%, or no more than 0.02% of the weight of the PFS-based material 200.
[0017] The method 100 optionally includes mixing the fluidized PFS-based mixture 204 with a resinous material at 108. Figure 3 illustrates mixing of the fluidized PFS-based mixture 204 shown in Figure 2 with a resinous material 300 according to one embodiment. The fluidized mixture 204 and the resinous material 300 are combined to form a flowing phosphor blend 302. The blend 302 may flow by being at least partially fluid until the blend 302 cures into a solid body. In one embodiment, the resinous material 300 is silicone, such as polydimethylsiloxane. Alternatively, another curable resinous material may be used.
[0018] The method 100 optionally includes placing the phosphor blend onto a light source at 110. Figure 4 illustrates placing the phosphor blend 302 onto a light source 400 according to one embodiment. The phosphor blend 302 may be injected onto the light source 400, such as a semiconductor-based light source (e.g., an LED), by injecting the blend 302 from a reservoir 402 through a nozzle 404 and onto the light source 400. Optionally, the blend 302 may be sprayed or otherwise dispensed from the nozzle 404. As shown in Figure 4, the blend 302 may at least partially encapsulate the light source 400. The blend 302 may then be cured to harden on or over the light source 400. The cured blend 302 forms the phosphor or phosphor body on the light source 400 that emits light responsive to receiving light generated by the light source 400.
[0019] The nozzle 404 may have a relatively small outlet or orifice through which the blend 302 exits the nozzle 404. The outlet may have a diameter of 70 microns or smaller. Without adding the fluidization material 202 to the PFS-based material 200, particles of the PFS-based material 200 in the blend 302 may clog the outlet of the nozzle 404 and prevent additional blend 302 from being dispensed from the nozzle 404. Addition of the fluidization material 202 to the PFS-based material 200 prevents this clogging from occurring.
[0020] The addition of the fluidization material 202 to the PFS-based material 200 can increase the loose density or bulk density of the of the fluidized PFS-based mixture 204, even at relatively small amounts of the fluidization material 202. Figure 5 illustrates loose densities 500 of the PFS-based material 200 in the PFS-based mixture 204 and internal quantum yields or quantum efficiencies (QY) 502 of the PFS-based mixture 204 for different weight percentages of fluidization material 202 in the mixture 204. The internal quantum yields or efficiencies may represent a ratio of the number of photons exiting a sample of the PFS-based mixture to the number of photons that are absorbed by the sample. The internal quantum yields or efficiencies may be measured by the FS5 spectrofluorometer with integrating sphere produced by Edinburgh Instruments. In the examples shown in Figure 5, the PFS-based material 200 is potassium hexafluorosilicate doped with tetravalent manganese and the fluidization material 202 is aluminum oxide. [0021] The loose densities 500 and the quantum yields 502 are shown alongside a horizontal axis 504 representative of different weight percentages of the aluminum oxide in the mixture 204 and alongside a first vertical axis 506 representative of different loose densities and alongside a second vertical axis 508 representative of different internal quantum yields or efficiencies.
[0022] As shown in Figure 5, addition of the fluidization material 202 to the PFS-based material 200 increases the loose density 500 of the PFS-based material 200 even at relatively low amounts (e.g., at 0.005% weight percentage). As the amount of the fluidization material 202 added to the PFS-based mixture 204 increases (e.g., amounts of 0.03% to 0.07% weight percentage), the loose density 500 becomes constant or substantially constant and is about 20% greater than the loose density 500 with no fluidization material 202 added to the PFS-based material 200. The quantum efficiency 502 of the PFS-based mixture 204 over this range is, within measurement error of powders, is constant or substantially constant.
[0023] Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one having ordinary skill in the art to which this disclosure belongs. The terms "first", "second", and the like, as used herein, do not denote any order, quantity, or importance, but rather are employed to distinguish one element from another. Also, the terms "a" and "an" do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. The use of "including," "comprising" or "having" and variations thereof herein, are meant to encompass the items listed thereafter and equivalents thereof, as well as additional items. The terms "connected" and "coupled" are not restricted to physical or mechanical connections or couplings, and can include electrical and optical connections or couplings, whether direct or indirect.
[0024] Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. The various features described, as well as other known equivalents for each feature, can be mixed and matched by one of ordinary skill in this art, to construct additional systems and techniques in accordance with principles of this disclosure.
[0025] In describing alternate embodiments of the apparatus claimed, specific terminology is employed for the sake of clarity. The invention, however, is not intended to be limited to the specific terminology so selected. Thus, it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions. [0026] It is noted that various non-limiting embodiments, described and claimed herein, may be used separately, combined, or selectively combined for specific applications.
[0027] Further, some of the various features of the above non-limiting embodiments may be used to advantage, without the corresponding use of other described features. The foregoing description should therefore be considered as merely illustrative of the principles, teachings and exemplary embodiments of this invention, and not in limitation thereof.
[0028] The limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112(f), unless and until such claim limitations expressly use the phrase "means for" followed by a statement of function void of further structure.

Claims

WHAT IS CLAIMED IS:
1. A method comprising:
mixing a potassium hexafluorosilicate-based powder with a fluidization material to form a potassium hexafluorosilicate-based mixture,
wherein the potassium hexafluorosilicate-based mixture is configured to be mixed with a resinous material to form a flowing phosphor blend configured to be placed onto a light source to form a phosphor on the light source.
2. The method of claim 1, further comprising mixing the potassium hexafluorosilicate-based mixture with the resinous material to form the flowing phosphor blend.
3. The method of claim 2, further comprising placing the flowing phosphor blend onto the light source to form the phosphor on the light source.
4. The method of claim 1, wherein the potassium hexafluorosilicate-based powder comprises potassium hexafluorosilicate doped with manganese.
5. The method of claim 4, wherein the manganese comprises Mn4+.
6. The method of claim 1, wherein the fluidization material includes a metal oxide powder.
7. The method of claim 1, wherein the fluidization material includes aluminum oxide.
8. The method of claim 1, wherein the fluidization material includes silica.
9. The method of claim 1, wherein the fluidization material is formed as sub-micron sized particles.
10. The method of claim 1, wherein the resinous material includes silicone.
11. The method of claim 1 , wherein the phosphor formed from the phosphor blend has a greater quantum efficiency relative to a phosphor formed from a phosphor blend that includes the potassium hexafluorosilicate-based powder and the resinous material and that does not include the fluidization material.
12. A method comprising:
mixing a potassium hexafluorosilicate-based powder with a metal oxide fluidization material to form a potassium hexafluorosilicate-based mixture, wherein the potassium hexafluorosilicate -based mixture is configured to be mixed with a resinous material to form a phosphor blend that is configured to form a phosphor of a light source.
13. The method of claim 12, further comprising mixing the potassium hexafluorosilicate-based mixture with the resinous material to form the flowing phosphor blend.
14. The method of claim 13, further comprising placing the flowing phosphor blend onto the light source to form the phosphor on the light source.
15. The method of claim 12, wherein the potassium hexafluorosilicate-based powder comprises potassium hexafluorosilicate doped with manganese.
16. The method of claim 15, wherein the manganese comprises Mn4+.
17. The method of claim 12, wherein the metal oxide fluidization material includes aluminum oxide.
18. The method of claim 12, wherein the metal oxide fluidization material is formed as sub- micron sized particles.
19. The method of claim 12, wherein the resinous material includes silicone.
20. The method of claim 12, wherein the phosphor formed from the phosphor blend has a greater quantum efficiency relative to a phosphor formed from a phosphor blend that includes the potassium hexafluorosilicate -based powder and the resinous material and that does not include the metal oxide fluidization material.
21. A phosphor body formed from: a potassium hexafluorosilicate-based powder;
a metal oxide fluidization material; and
a resinous material.
22. The phosphor body of claim 21, wherein the potassium hexafluorosilicate-based powder comprises potassium hexafluorosilicate doped with manganese.
23. The phosphor body of claim 22, wherein the manganese comprises Mn4+.
24. The phosphor body of claim 21, wherein the metal oxide fluidization material includes aluminum oxide.
25. The phosphor body of claim 21, wherein the metal oxide fluidization material is formed as sub-micron sized particles.
26. The phosphor body of claim 21, wherein the resinous material includes silicone.
27. The phosphor body of claim 21, wherein the phosphor body has a greater quantum efficiency relative to another phosphor body formed from a phosphor blend that includes the potassium hexafluorosilicate-based powder and the resinous material and that does not include the metal oxide fluidization material.
28. A method comprising:
obtaining a flowing phosphor blend of a mixture of a potassium hexafluorosilicate-based powder, a fluidization material, and a resinous material, the blend configured to be placed onto a light source to form a phosphor on the light source; and
dispensing the flowing phosphor blend out of a nozzle onto the light source.
29. The method of claim 28, wherein the nozzle has an outlet through which the flowing phosphor blend is dispensed, the outlet having an opening of no more than about 70 microns.
PCT/US2017/029534 2016-05-02 2017-04-26 Phosphor materials for light sources and method for fluidizing the same Ceased WO2017192322A1 (en)

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MYPI2018703719A MY186678A (en) 2016-05-02 2017-04-26 Phosphor materials including fluidization materials for light sources
JP2018557420A JP7244277B2 (en) 2016-05-02 2017-04-26 Phosphor material for light source and method for fluidizing same
CN202510062592.8A CN119875627A (en) 2016-05-02 2017-04-26 Phosphor material for light source and method for fluidization thereof
KR1020187034565A KR102379088B1 (en) 2016-05-02 2017-04-26 Phosphorescent material for light source and method for fluidizing same
CN201780027462.4A CN109072074A (en) 2016-05-02 2017-04-26 Phosphor material for light source and method for fluidizing it
MX2018013328A MX2018013328A (en) 2016-05-02 2017-04-26 PHOSPHORY MATERIALS FOR LIGHT SOURCES AND METHOD FOR FLUIDIZING THE SAME.
CA3021557A CA3021557C (en) 2016-05-02 2017-04-26 Phosphor materials for light sources and method for fluidizing the same
DE112017002296.7T DE112017002296T5 (en) 2016-05-02 2017-04-26 Fluorescent materials for light sources and methods for fluid make the same

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