WO2022030397A1 - 蛍光体塗料、塗膜、蛍光体基板および照明装置 - Google Patents
蛍光体塗料、塗膜、蛍光体基板および照明装置 Download PDFInfo
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- WO2022030397A1 WO2022030397A1 PCT/JP2021/028400 JP2021028400W WO2022030397A1 WO 2022030397 A1 WO2022030397 A1 WO 2022030397A1 JP 2021028400 W JP2021028400 W JP 2021028400W WO 2022030397 A1 WO2022030397 A1 WO 2022030397A1
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- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/50—Wavelength conversion elements
- H01L33/501—Wavelength conversion elements characterised by the materials, e.g. binder
- H01L33/502—Wavelength conversion materials
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/04—Polysiloxanes
- C08G77/14—Polysiloxanes containing silicon bound to oxygen-containing groups
- C08G77/16—Polysiloxanes containing silicon bound to oxygen-containing groups to hydroxyl groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
- C08G77/80—Siloxanes having aromatic substituents, e.g. phenyl side groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2300/00—Characterised by the use of unspecified polymers
- C08J2300/12—Polymers characterised by physical features, e.g. anisotropy, viscosity or electrical conductivity
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2383/00—Characterised by the use of 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; Derivatives of such polymers
- C08J2383/04—Polysiloxanes
- C08J2383/06—Polysiloxanes containing silicon bound to oxygen-containing groups
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2483/00—Characterised by the use of 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; Derivatives of such polymers
- C08J2483/04—Polysiloxanes
- C08J2483/06—Polysiloxanes containing silicon bound to oxygen-containing groups
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/50—Wavelength conversion elements
- H01L33/501—Wavelength conversion elements characterised by the materials, e.g. binder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
- H01L33/50—Wavelength conversion elements
- H01L33/501—Wavelength conversion elements characterised by the materials, e.g. binder
- H01L33/502—Wavelength conversion materials
- H01L33/504—Elements with two or more wavelength conversion materials
Definitions
- the present invention relates to a fluorescent paint, a coating film, a fluorescent substrate and a lighting device.
- LEDs Light Emitting Devices
- Example 2 of Patent Document 1 (i) a glass binder paint containing a 30 vol% phosphor was applied to the surface of a glass substrate to form a phosphor layer having a thickness of 200 ⁇ m (ii). )
- a mounting board for LED lighting by joining multiple CSPs on the glass substrate.
- CSP Chip Scale Package or Chip Size Package, and the LED chip is wrapped in a fluorescent resin and is packageless with only the LED chip and the fluorescent resin.
- Example 2 of Patent Document 1 a "glass binder paint" containing a fluorescent substance is used to form a fluorescent substance layer having a thickness of 200 ⁇ m on a glass substrate.
- a sintering step at a high temperature is usually required to sufficiently cure the glass binder paint, there is room for improvement in terms of the convenience of providing the phosphor layer.
- the housing / substrate to which the glass binder paint is applied is also limited in heat resistance, optimization of expansion coefficient, and the like.
- the present invention was made in view of such circumstances.
- One of the objects of the present invention is to provide a material capable of easily forming a phosphor layer.
- a fluorescent paint containing fluorescent particles and a curable resin component A fluorescent paint having a viscosity of 60 dPa ⁇ s or more and 450 dPa ⁇ s or less measured at 25 ° C. and a rotation speed of 20 rpm using a B-type viscometer is provided.
- a coating film formed by the above fluorescent paint is provided.
- a fluorescent substrate having the above coating film is provided.
- a lighting device including an insulating substrate, a coating film provided on one side of the insulating substrate by the above-mentioned phosphor paint, and a light emitting element installed on the surface of the coating film opposite to the insulating substrate. Will be done.
- the fluorescent layer can be easily provided.
- (meth) acrylic herein represents a concept that includes both acrylic and methacrylic.
- fluorescent particles herein may mean “fluorescent powder” which is an aggregate of fluorescent particles, depending on the context. For example, “the median diameter D 50 of the phosphor particles” described later is a value obtained based on the particle size distribution of the phosphor powder which is an aggregate of the phosphor particles.
- the fluorescent paint of the present embodiment contains fluorescent particles and a curable resin component.
- the viscosity of the fluorescent paint of the present embodiment measured using a B-type viscometer at 25 ° C. and a rotation speed of 20 rpm is 60 dPa ⁇ s or more and 450 dPa ⁇ s or less.
- the content of the fluorescent particles in the total non-volatile components is 25 vol% or more and 60 vol% or less.
- the fluorescent paint of this embodiment contains a curable "resin component" instead of a glass binder.
- the fluorescent layer can be provided relatively easily without requiring sintering at a high temperature.
- the usable phosphors are not limited. Specifically, when trying to obtain a cured film with a glass binder, it is necessary to bake at a high temperature of about 600 ° C. When such a high temperature is required, it is necessary to select a fluorescent material that can withstand the high temperature, which may limit the fluorescent materials that can be used. In addition, peeling is likely to occur when cooling from a high temperature. However, by preparing the fluorescent paint using the curable resin component, it is possible to form a fluorescent layer in which peeling is unlikely to occur without requiring a high temperature of about 600 ° C. The fact that sintering at a high temperature is not required also leads to the merit that there are few restrictions on the heat resistance and the optimization of the expansion coefficient of the housing / substrate on which the paint is applied or printed.
- the curable resin component it is easy to form an appropriately thin phosphor layer by coating or printing. This is particularly effective when the content of the fluorescent particles in the fluorescent paint is large.
- the viscosity is 60 dPa ⁇ s or more and 450 dPa ⁇ s or less, for example, by a screen printing method suitable for mass production, a phosphor layer (coating containing phosphor particles) having an appropriate thickness and less unevenness is used. A film) can be formed on the substrate.
- a fluorescent paint having a viscosity of 60 dPa ⁇ s or more and 450 dPa ⁇ s or less can be obtained by using an appropriate amount of an appropriate material.
- the fluorescent paint of the present embodiment is used by using an appropriate amount of fluorescent particles having an appropriate particle size distribution, using an appropriate amount of an appropriate fluidity adjusting agent, using an appropriate solvent, and the like. Can be manufactured.
- the fluorescent paint of the present embodiment contains fluorescent particles.
- the phosphor particles may be any particles that fluoresce due to the light emitted from the light emitting element. Depending on the desired color, color temperature, etc., only one specific fluorescent particle may be used, or two or more fluorescent particles may be used in combination.
- the fluorescent substance particles include a CASN-based phosphor, a SCASN-based phosphor, a La 3 Si 6 N 11 -based phosphor, an Sr 2 Si 5 N 8 -based phosphor, a Ba 2 Si 5 N 8 -based phosphor, and an ⁇ -type sialon-based fluorophore.
- a fluorescent substance a ⁇ -type sialon-based fluorescent substance, a LuAG-based fluorescent substance, and a YAG-based fluorescent substance can be mentioned.
- These phosphors usually contain activating elements such as Eu and Ce.
- the CASN-based fluorophore (a type of nitride fluorophore) preferably contains Eu.
- the CASN-based fluorophore is, for example, a red fluorophore represented by the formula CaAlSiN 3 : Eu 2+ , using Eu 2+ as an activator and having a crystal made of an alkaline earth silicate as a base.
- the SCASN-based fluorophore containing Eu is excluded.
- the SCASSN-based fluorophore (a type of nitride fluorophore) preferably contains Eu.
- the SCASSN-based phosphor is, for example, a red phosphor represented by the formula (Sr, Ca) AlSiN 3 : Eu 2+ , using Eu 2+ as an activator and a crystal made of an alkaline earth silicate as a base.
- the La 3 Si 6 N 11 system phosphor is a La 3 Si 6 N 11 : Ce phosphor or the like. This usually wavelength-converts the blue light from the blue LED into yellow light.
- Sr 2 Si 5 N 8 system phosphor examples include Sr 2 Si 5 N 8 : Eu 2+ phosphor, Sr 2 Si 5 N 8 : Ce 3 + phosphor, and the like. These usually wavelength-convert the blue light from the blue LED into yellow to red light.
- the Ba 2 Si 5 N 8 system phosphor is Ba 2 Si 5 N 8 : Eu. This usually wavelength-converts the blue light from the blue LED into orange to red light.
- the ⁇ -type sialone-based phosphor preferably contains Eu.
- the ⁇ -type sialon containing Eu is represented by, for example, the general formula: M x Eu y Si 12- (m + n) Al (m + n) On N 16-n .
- M is one or more elements containing at least Ca selected from the group consisting of Li, Mg, Ca, Y and lanthanide elements (excluding La and Ce), and the valence of M is a.
- ax + 2y m
- x is 0 ⁇ x ⁇ 1.5, 0.3 ⁇ m ⁇ 4.5, and 0 ⁇ n ⁇ 2.25.
- the ⁇ -type sialone-based fluorophore preferably contains Eu.
- the ⁇ -type sialon containing Eu is represented by, for example, the general formula Si 6-z Al z Oz N 8-z : Eu 2+ (0 ⁇ Z ⁇ 4.2), from the ⁇ -type sialon in which Eu 2+ is solid-solved. It is a fluorescent substance.
- the Z value and the content of europium are not particularly limited. The Z value is, for example, more than 0 and 4.2 or less, and is preferably 0.005 or more and 1.0 or less from the viewpoint of further improving the emission intensity of ⁇ -type sialon. Further, the content of europium is preferably 0.1% by mass or more and 2.0% by mass or less.
- the LuAG-based phosphor usually means a lutetium aluminum garnet crystal.
- LuAG is preferably a LuAG: Ce phosphor. More specifically, LuAG can be expressed by the composition formula of Lu 3 Al 5 O 12 : Ce, but the composition of LuAG does not necessarily have to follow stoichiometry.
- the YAG-based phosphor usually means yttrium aluminum garnet crystals. Considering the application to a lighting device, the YAG-based phosphor is preferably activated by Ce. More specifically, the YAG-based phosphor can be represented by the composition formula of Y3 Al 5 O 12 : Ce, but the composition of the YAG-based phosphor does not necessarily have to follow stoichiometry.
- phosphor particles Commercially available products may be used as the phosphor particles.
- fluorescent particles include Aron Bright (registered trademark) of Denka Corporation. In addition, it is also commercially available from Mitsubishi Chemical Corporation.
- the median diameter D 50 of the phosphor particles is preferably 1 ⁇ m or more and 20 ⁇ m or less, and more preferably 5 ⁇ m or more and 15 ⁇ m or less.
- a maximum of 2 or more is observed in the particle size distribution curve of the phosphor particles. Specifically, it is preferable that a maximum is observed in both the region having a particle size of 1 ⁇ m or more and 6 ⁇ m or less and the region having a particle size of 10 ⁇ m or more and 25 ⁇ m or less.
- the presence of two or more maxima means that the fluorophore particles contain both large and small particles. Since the small particles enter the "gap" between the large particles, it is easy to increase the content of the phosphor particles as compared with the case where only the large particles are used. Further, even if the content of the phosphor particles is increased, it is easy to maintain various physical properties as a paint. Further, when the coating film is used, the light emitted from the light emitting element is less likely to be transmitted.
- the particle size distribution curve of the phosphor particles can be measured by a laser diffraction / scattering type particle size distribution measuring device after the raw material phosphor particles are dispersed in a dispersion medium with an ultrasonic homogenizer. Then, the median diameter D 50 can be obtained from the obtained particle size distribution curve.
- the median diameter D50 and the particle size distribution curve are measured on a volume basis.
- the fluorescent paint of the present embodiment may contain only one kind of fluorescent particles, or may contain two or more kinds of fluorescent particles.
- the content of the fluorescent particles in the total non-volatile components of the fluorescent paint is, for example, 25 vol% or more and 60 vol% or less. This content is preferably 30 vol% or more and 60 vol% or less, more preferably 35 vol% or more and 60 vol% or less, and further preferably 40 vol% or more and 50 vol% or less.
- the content of the phosphor particles in all the non-volatile components of the phosphor paint By setting the content of the phosphor particles in all the non-volatile components of the phosphor paint to 25 vol% or more, for example, the light emitted from the light emitting element can be sufficiently converted into fluorescence. In addition, as another merit, there is a further improvement in coating or printability.
- the content of the fluorescent particles in the fluorescent paint is moderately large, the fluorescent paint is less likely to flow moderately, and as a result, it becomes easy to form a fluorescent layer having an appropriate film thickness.
- the content of the fluorescent particles in all the non-volatile components of the fluorescent paint By setting the content of the fluorescent particles in all the non-volatile components of the fluorescent paint to 25 vol% or more, there is also an advantage that cracks are less likely to occur in the fluorescent layer.
- one of the causes of crack generation is considered to be the difference in thermal expansion rate between the phosphor layer and the substrate on which the phosphor layer is provided.
- the curable resin component is relatively reduced. Then, the difference between the thermal expansion rate of the phosphor layer and the thermal expansion rate of the substrate on which the phosphor layer is provided becomes small. As a result, it is considered that cracks are less likely to occur in the phosphor layer.
- the light emitted from the light emitting element can be sufficiently converted into fluorescence.
- the color temperature of the light emitted from the light emitting element can be greatly converted.
- the content of the fluorescent particles in all the non-volatile components of the fluorescent paint is preferably 60 vol% or less.
- the fluorescent paint of this embodiment contains a curable resin component.
- the "curable resin component” is not only (1) a resin (polymer) component having a property of being cured by the action of heat, light, etc., but also (2) a monomer or an oligomer before forming a coating film. However, it also contains a component capable of forming a resin (polymer) by increasing the molecular weight by the action of heat, light, etc. after forming the coating film.
- a polymerization initiator, a curing agent and the like are also included in the "curable resin component”.
- the curable resin component contains a resin, monomer or oligomer
- these are usually organic substances. That is, the curable resin component usually contains an organic resin, an organic monomer or an organic oligomer.
- the curable resin component preferably contains a thermosetting resin component. This makes it possible to manufacture a highly durable lighting device.
- the curable resin component may include a thermoplastic resin.
- the curable resin component preferably contains 1 or 2 or more selected from the group consisting of silicone resin and (meth) acrylate monomer.
- a silicone resin a resin having a siloxane bond as a main skeleton
- heat resistance and durability a silicone resin (a resin having a siloxane bond as a main skeleton) is preferable from the viewpoint of heat resistance and durability.
- the curable resin component preferably contains a silicone resin having a phenyl group and / or a methyl group.
- a silicone resin is preferable in terms of compatibility with other components, solvent solubility, coatability, heat resistance, durability and the like.
- the ratio of phenyl group: methyl group in this resin is, for example, about 0.3: 1 to 1.5: 1.
- the curable resin component can contain reactive groups. Thereby, the curable resin component can be cured by itself.
- the curable resin component preferably contains a silicone resin containing a silanol group (—Si—OH). As a result, a silanol group condensation reaction occurs during the formation of the coating film, and a cured coating film is obtained.
- the silanol content (OH% by mass) of the silicone resin containing a silanol group (—Si—OH) is, for example, 0.1% by mass or more and 5% by mass or less.
- the curable resin component may be one that is cured by a hydrosilylation reaction between a vinyl group-containing polymer and a Si—H group-containing silicone polymer (addition reaction type).
- the weight average molecular weight of the resin contained in the curable resin component is not particularly limited. As long as a coating film can be formed as a coating material, a resin having an arbitrary weight average molecular weight can be contained. As an example, the weight average molecular weight of the resin contained in the curable resin component is usually 1,000 or more and 1,000,000 or less, preferably 1,000 or more and 500,000 or less. When a commercially available product is used as the resin contained in the curable resin component, catalog data can be adopted as the weight average molecular weight of the resin. When the weight average molecular weight is unknown from a catalog or the like, it can be obtained by, for example, gel permeation chromatography (GPC) measurement using polyethylene as a standard material.
- GPC gel permeation chromatography
- a commercially available product may be used as the resin contained in the curable resin component.
- Commercially available silicone resins can be obtained from, for example, Toray Dow Corning, Shin-Etsu Chemical, and the like.
- RSN-0409, RSN-0431, RSN-0804, RSN-0805, RSN-0806, RSN-0808, RSN-0840, etc. manufactured by Toray Dow Corning
- KF-8010, X-22-161A, KF-105 , X-22-163A, X-22-169AS, KF-6001, KF-2200, X-22-164A, X-22-162C, X-22-167C, X-22-173BX, etc. (Shin-Etsu Chemical Co., Ltd.) Made) can be mentioned.
- the curable resin component may contain a monomer or an oligomer instead of the resin.
- the curable resin component preferably contains a (meth) acrylate monomer.
- the (meth) acrylate monomer may be monofunctional or polyfunctional.
- the (meth) acrylate monomer preferably has 2 or more and 6 or less (meth) acrylic structures in one molecule.
- the curable resin component preferably contains a polymerization initiator together with the monomer and the oligomer.
- a polymerization initiator for example, when the curable resin component contains a (meth) acrylate monomer, it is preferably used in combination with a radical polymerization initiator.
- the radical polymerization initiator generates radicals by heat or active light.
- the curable resin component can be a silicone resin as described above, a combination of a (meth) acrylate monomer and a polymerization initiator, or any component known in the paint field.
- the curable resin component may be, for example, a urethane-based one containing (i) a polyol and a polyisocyanate, or (ii) an epoxy-based one.
- polyol (i) examples include (meth) acrylic polyol, polyester polyol, polyether polyol, epoxy polyol, polyolefin-based polyol, fluorine-containing polyol, polycaprolactone polyol, polycaprolactam polyol, polycarbonate polyol and the like.
- polyisocyanate of (i) preferably 2 to 6 functional, more preferably 2 to 4 functional can be mentioned.
- Specific examples thereof include aliphatic diisocyanates, cyclic aliphatic diisocyanates, isocyanurates and biuret-type adducts which are multimers of isocyanate compounds, and isocyanate compounds added to polyhydric alcohols or low molecular weight polyester resins. ..
- a biuret type, an isocyanurate type, an adduct type, an allophanate type and the like are also known. Any of these can be used.
- the polyisocyanate of (i) may be a so-called blocked isocyanate.
- some or all of the isocyanate groups of the polyisocyanate may be in the form of blocked isocyanate groups blocked by protecting groups.
- active hydrogen compounds such as alcohol-based, phenol-based, lactam-based, oxime-based, and active methylene-based active hydrogen compounds block isocyanate groups to form blocked isocyanate groups.
- polyisocyanate Commercially available products of polyisocyanate include, for example, Duranate (trade name) series manufactured by Asahi Kasei Corporation, Takenate (trade name) series manufactured by Mitsui Chemicals, Inc., and Death Module (trade name) series manufactured by Sumika Bayer Urethane Co., Ltd. And so on.
- the epoxy-based curable resin component of (ii) usually contains an epoxy resin and a curing agent thereof.
- the epoxy resin include bisphenol A type epoxy resin, halogenated bisphenol A type epoxy resin, novolak type epoxy resin, polyglycol type epoxy resin, bisphenol F type epoxy resin, epoxidized oil, 1,6-hexanediol diglycidyl ether, and the like. Examples thereof include neopentyl glycol diglycidyl ether.
- the curing agent usually include polyamines such as polyvalent amines, amine adducts, and polyamides, and acid anhydrides.
- the fluorescent paint of the present embodiment may contain only one type of curable resin component, or may contain two or more types.
- the amount of the curable resin component in the fluorescent paint of the present embodiment is preferably 40 vol% or more and 65 vol% or less, and more preferably 45 vol% or more and 60 vol% or less in the total non-volatile components.
- the fluorescent paint of the present embodiment preferably contains a fluidity adjusting agent.
- a fluidity adjusting agent for example, thixotropic property, etc.
- silica particles such as hydrophobic silica and hydrophilic silica, aluminum oxide and the like can be applied.
- fumed silica is preferably used.
- Commercially available fluidity modifiers include, for example, AEROSIL 130, AEROSIL 200, AEROSIL 300, AEROSIL R-972, AEROSIL R-812, AEROSIL R-812S, ArminiumExideC (manufactured by Aerosil Japan, AEROSIL is a registered trademark), Carplex FPS. -1 (manufactured by DSL, product name) and the like can be mentioned.
- the fluorescent paint of the present embodiment may contain only one kind of the fluidity adjusting agent, or may contain two or more kinds of the fluidity adjusting agent.
- the amount thereof is, for example, 10 vol% or less, preferably 1 vol% or more and 5 vol% or less, in the total non-volatile components.
- the amount of the fluidity modifier is, for example, 5 mass% or less, preferably 0.1 mass% or more and 5 mass% or less, in the total non-volatile components.
- the fluorescent paint of the present embodiment preferably contains a solvent. This makes it possible to obtain a fluorescent paint having good coatability.
- Solvents include water and / or organic solvents. Examples of the organic solvent include hydrocarbon solvents, ketone solvents, ester solvents, alcohol solvents, amide solvents, ether solvents and the like.
- Preferable organic solvent includes alcohol solvent. Specific examples thereof include methanol, ethanol, n-propanol, 2-propanol, n-butanol, 2-butanol, t-butanol and the like. Further, ether bond-containing alcohols such as butyl carbitol (diethylene glycol monobutyl ether) and ethyl carbitol (diethylene glycol monoethyl ether) are also preferably mentioned. These are particularly preferable in that when a silicone resin is used as the resin, the silicone resin can be well dissolved / dispersed to prepare a fluorescent paint having good coatability.
- alcohol solvent includes methanol, ethanol, n-propanol, 2-propanol, n-butanol, 2-butanol, t-butanol and the like.
- ether bond-containing alcohols such as butyl carbitol (diethylene glycol monobutyl ether) and ethyl carbitol
- the solvent preferably contains an aromatic hydrocarbon solvent.
- an aromatic hydrocarbon solvent examples include toluene, xylene and the like.
- a solvent When a solvent is used, only one kind of solvent may be used, or two or more kinds of solvents may be used in combination.
- the above-mentioned alcohol solvent and aromatic hydrocarbon solvent may be used in combination.
- a solvent it is preferable that at least 1% by mass of each solvent is present in the total amount of the solvent, from the viewpoint of sufficiently obtaining the effect of the combined use.
- the fluorescent paint of the present embodiment contains a solvent, it is preferable that the solvent is contained in an amount such that the concentration of the non-volatile component is 90% by mass or less.
- the concentration of the non-volatile component is not limited to this, and the amount may be appropriately adjusted as long as the coating film can be formed.
- the fluorescent paint of the present embodiment may contain other components other than the above.
- Other components include rust preventive pigments, extender pigments, surface conditioners, waxes, defoamers, dispersants, UV absorbers, light stabilizers, antioxidants, leveling agents, anti-benwaki agents, plasticizers, and charge control agents. And so on.
- the viscosity of the fluorescent paint of the present embodiment measured at 25 ° C. and a rotation speed of 20 rpm using a B-type viscometer is 60 dPa ⁇ s or more and 450 dPa ⁇ s or less.
- the viscosity is preferably 80 dPs ⁇ s or more and 350 dPa ⁇ s or less, and more preferably 90 dPs ⁇ s or more and 320 dPa ⁇ s or less.
- a phosphor layer having an appropriate thickness can be formed, in particular, by a screen printing method.
- the fluorescent paint of the present embodiment may be a one-component type or a multi-component type of two or more liquids.
- the film-forming resin composition of the present embodiment can be supplied as a one-component composition in which all the necessary components are uniformly mixed or dispersed.
- the film-forming resin composition of the present embodiment may be supplied as a two-component type (two-component kit) of a liquid A containing a part of the components and a liquid B containing the remaining components. From the viewpoint of storage stability before being used for painting, it may be preferable to use a multi-component fluorescent material.
- each liquid is uniformly mixed immediately before forming a coating film to obtain a paint for painting.
- the viscosity of the paint for painting is set to be 60 dPa ⁇ s or more and 450 dPa ⁇ s or less.
- the above fluorescent paint can be used to form a coating film containing fluorescent particles.
- the above-mentioned fluorescent material paint can be used to manufacture a fluorescent material substrate having a coating film containing fluorescent material particles.
- a lighting device including an element (LED element or the like) can be manufactured.
- the coating film, the phosphor substrate, and the lighting device will be described while illustrating a configuration example of the lighting device.
- FIG. 1 is a schematic cross-sectional view of a lighting device.
- the fluorescent coating film 26 is provided on one surface of the insulating substrate 20.
- a first copper foil 22 and a white layer 24 are provided between the insulating substrate 20 and the fluorescent coating film 26 in order from the side of the insulating substrate 20.
- a part of the first copper foil 22 is removed by etching, and functions as a copper circuit (copper wiring).
- a surface mount type LED element 28 (light emitting element) is installed on the surface of the fluorescent coating film 26 opposite to the insulating substrate 20.
- the surface mount type LED element 28 is electrically connected to the first copper foil 22 by a solder 30 provided so as to penetrate the white layer 24 and the fluorescent coating film 26. Electricity is supplied to the surface mount type LED element 28 by the first copper foil 22 and the solder 30, and the surface mount type LED element 28 emits light.
- a white layer 32 more specifically, a white resin layer 32
- the lighting device of FIG. 1 can include a plurality of surface mount type LED elements 28.
- the second copper foil 22B can be provided on the other surface of the insulating substrate 20 (the surface opposite to the side on which the fluorescent coating film 26 is provided).
- the material of the insulating substrate 20 is not particularly limited as long as it can be used for a PWB (printed circuit board).
- a PWB printed circuit board
- polyimide resin, silicone resin, (meth) acrylic resin, urea resin, epoxy resin, fluororesin, glass, metal (aluminum, copper, iron, stainless steel, etc.) can be used.
- polyimide resin, silicone resin, glass or metal such as a so-called "metal substrate” in which aluminum or copper is used as a base metal and an insulating layer is provided
- the thickness of the insulating substrate 20 is not particularly limited as long as it can be used for lighting equipment. For example, it is 50 ⁇ m or more and 1000 ⁇ m or less, specifically, 50 ⁇ m or more and 500 ⁇ m or less.
- the white layer 24 and the white layer 32 can be provided by using, for example, a white paint.
- the composition and properties of the white paint are not particularly limited as long as the white layer 24 can be formed.
- a coating composition using a white pigment instead of the fluorescent substance particles can be mentioned.
- the coating method can be the same as that of the fluorescent coating film 26 described below.
- the white pigment include known pigments such as titanium oxide. Inorganic pigments are preferable from the viewpoint of stability and the like.
- the thickness of the white layer 24 is, for example, 10 ⁇ m or more and 500 ⁇ m or less, specifically 20 ⁇ m or more and 400 ⁇ m or less.
- the fluorescent coating film 26 can be provided by applying the above coating composition.
- the fluorescent coating film 26 converts the light emitted from the light emitting element into light having a different wavelength / color temperature.
- the coating method is not particularly limited.
- a preferred method is a printing method such as a screen printing method.
- the viscosity of the coating composition is 60 dPa ⁇ s or more and 450 dPa ⁇ s or less, a uniform fluorescent coating film 26 having an appropriate thickness can be provided by applying the screen printing method.
- the coating method may be another method, and the coating composition may be applied using, for example, various coaters known in the coating field. After coating, it is preferable to perform a drying treatment or a curing treatment.
- the conditions for the drying treatment are, for example, 60 ° C. or higher and 100 ° C. or lower for 15 minutes or longer and 60 minutes or shorter.
- the conditions for the curing treatment are, for example, 100 ° C. or higher and 200 ° C. or lower for 30 minutes or longer and 240 minutes or shorter.
- the coating amount of the coating composition is adjusted so that the thickness of the fluorescent coating film 26 in the lighting device as a finished product is preferably 150 ⁇ m or less, more preferably 30 ⁇ m or more and 100 ⁇ m or less, and further preferably 30 ⁇ m or more and 80 ⁇ m or less. .. Since the content of the fluorescent substance particles in the coating composition is 25 vol% or more, preferably 30 vol% or more, more preferably 35 vol% or more, even if the thickness of the fluorescent coating film 26 is 150 ⁇ m or less, it is a surface mount type. The light emitted from the LED element 28 can be sufficiently converted into fluorescence, and the light emitted from the surface mount type LED element 28 does not easily pass through the phosphor layer.
- holes through which the solder 30 penetrates can be provided.
- a known method can be appropriately applied to the subsequent connection between the surface mount type LED element 28 (light emitting element) and the first copper foil 22 by the solder 30.
- the surface mount type LED element 28 includes a CSP, an SMD (Surface Mount Device), and a flip chip element.
- the light emitting device is preferably CSP. Further, the light emitting element usually emits blue light.
- the light emitting element does not include a reflector.
- the known surface mount type LED element (light emitting element) is provided with a reflector, so that light from the LED chip leaks in the lateral direction or the downward direction.
- the surface mount type LED element 28 (light emitting element) does not include a reflector as shown in FIG. 2B.
- the semiconductor light emitting element 100 is arranged in the package-shaped portion 108 formed by the substrate 102 and the reflector (housing) 104, and the sealing member 110 (light-transmitting resin) is arranged in the package-shaped portion 108. ) Is filled.
- the board 102 can include wiring 112.
- FIG. 2B the same elements as those in FIG. 2A are designated by the same reference numerals.
- a housing reflector
- the sealing member 110 can be formed by molding using a desired mold. Alternatively, a sealing member 110 molded into a desired shape may be prepared in advance and adhered to the substrate 102 so as to cover the semiconductor light emitting device 100.
- the particle size distribution (D 50 ) of the phosphor particles was measured as follows. (1) Dispersion treatment by ultrasonic waves A dispersion liquid in which 30 mg of phosphor particles were uniformly dispersed in 100 mL of a sodium hexametaphosphate aqueous solution adjusted to a 0.2% mass was placed in a columnar container having a bottom surface with a radius of 2.75 cm. ..
- a lighting device having the structure described in FIG. 1 (a plurality of CSPs arranged on a phosphor layer at regular intervals) was produced.
- the manufacturing procedure is briefly shown below.
- a white paint having a thickness of 40 ⁇ m was formed on the first copper foil by using a white paint (a silicone binder kneaded with titanium oxide / alumina at 50 vol%).
- a white paint a silicone binder kneaded with titanium oxide / alumina at 50 vol%).
- the above fluorescent paint is printed (film formed) on the white layer by a screen printing method using a screen having 86 meshes, pre-cured at 80 ° C. for 30 minutes, and then 60 at 180 ° C. Minute post-cured (mainly cured). This formed a phosphor layer. At this time, the thickness of the phosphor layer was aimed at 50 ⁇ m.
- a part of the white layer and the phosphor layer was drilled to provide holes for soldering.
- Color temperature conversion> An electric current was passed through the lighting device manufactured above to make the lighting device emit light.
- the color temperature of the light emitted from the lighting device was measured using a total luminous flux measurement system (a device equipped with an integrating sphere) manufactured by Otsuka Electronics Co., Ltd.
- the color temperature conversion property was evaluated as good ( ⁇ ).
- the measured color temperature was 2100 to 2200K and the color temperature conversion remained within 100K, it was evaluated that the color temperature conversion property was insufficient (x). This evaluation was not performed in Comparative Example 2 in which the properties of the phosphor layer were abnormal.
- composition and evaluation results of the fluorescent paint are summarized in the table below.
- the phosphor layer could be formed by a relatively low temperature treatment of about 180 ° C. without requiring sintering at a high temperature unlike a binder. In addition, the appearance and durability of the formed fluorescent layer were good. Further, the formed phosphor layer greatly converted the color temperature of the light emitted from the CSP.
- Insulation substrate 22 First copper foil 22B Second copper foil 24 White layer 26 Fluorescent coating film 28 Surface mount type LED element 30 Solder 32 White layer (white resin layer) 100 Semiconductor light emitting element 102 Substrate 104 Reflector (housing) 108 Package-shaped part 110 Sealing member 112 Wiring
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Abstract
Description
(CSPとは、Chip Scale PackageまたはChip Size Packageの略で、LEDチップを蛍光体樹脂で包み、LEDチップと蛍光体樹脂だけの構成でパッケージレスとしたものである。)
蛍光体粒子と、硬化性樹脂成分と、を含む蛍光体塗料であって、
B型粘度計を用い、25℃、回転数20rpmで測定される粘度が60dPa・s以上450dPa・s以下である蛍光体塗料が提供される。
上記の蛍光体塗料により形成された塗膜
が提供される。
上記の塗膜を備える蛍光体基板
が提供される。
絶縁基板と、上記の蛍光体塗料により前記絶縁基板の片面側に設けられた塗膜と、前記塗膜における前記絶縁基板と反対側の面に設置された発光素子と、を備える照明装置
が提供される。
すべての図面において、同様な構成要素には同様の符号を付し、適宜説明を省略する。
すべての図面はあくまで説明用のものである。図面中の各部材の形状や寸法比などは、必ずしも現実の物品と対応しない。
本明細書における「蛍光体粒子」の語は、文脈により、蛍光体粒子の集合体である「蛍光体粉末」を意味する場合がある。例えば、後述の「蛍光体粒子のメジアン径D50」は、蛍光体粒子の集合体である蛍光体粉末の粒径分布に基づき求められる値である。
本実施形態の蛍光体塗料は、蛍光体粒子と硬化性樹脂成分とを含む。
本実施形態の蛍光体塗料を、B型粘度計を用い、25℃、回転数20rpmの条件で測定したときの粘度は、60dPa・s以上450dPa・s以下である。
全不揮発成分中の蛍光体粒子の含有率は、25vol%以上60vol%以下である。
高温での焼結を要しないということは、塗料を塗布または印刷する筐体/基板の、耐熱性や膨張係数最適化等の制限が少ないというメリットにもつながる。
とりわけ、本実施形態においては、粘度が60dPa・s以上450dPa・s以下であることにより、例えば大量生産に向くスクリーン印刷法によって、適度な厚みでムラが少ない蛍光体層(蛍光体粒子を含む塗膜)を基板上に形成することができる。
本実施形態の蛍光体塗料は、蛍光体粒子を含む。蛍光体粒子は、発光素子から発せられる光により蛍光を発するものであればよい。所望の色目・色温度などに応じて、特定の蛍光体粒子を1種のみ用いてもよいし、2以上の蛍光体粒子を併用してもよい。
本明細書におけるEuを含有するCASN系蛍光体の定義では、Euを含有するSCASN系蛍光体は除かれる。
念のため述べておくと、本明細書において、メジアン径D50や粒径分布曲線は、体積基準で測定される。
蛍光体塗料の全不揮発成分中の蛍光体粒子の含有率は、例えば25vol%以上60vol%以下である。この含有率は、好ましくは30vol%以上60vol%以下、より好ましくは35vol%以上60vol%以下、さらに好ましくは40vol%以上50vol%以下である。
また、それ以外のメリットとして、塗布または印刷適性の一層の向上が挙げられる。蛍光体塗料中の蛍光体粒子の含有率が適度に大きいことにより、蛍光体塗料が適度に流動しにくくなり、その結果、適度な膜厚の蛍光体層を形成しやすくなる。
蛍光体塗料の全不揮発成分中の蛍光体粒子の含有率を25vol%以上とすることにより、蛍光体層にクラックが発生しにくくなるというメリットもある。一般的な知見に基づけば、クラック発生の原因の1つは、蛍光体層と、蛍光体層を設ける基板との熱膨張率の差と考えられる。蛍光体塗料の全不揮発成分中の蛍光体粒子の含有率を25vol%以上とすることにより、相対的に硬化性樹脂成分が減る。そして、蛍光体層の熱膨張率と、蛍光体層を設ける基板の熱膨張率の差が小さくなる。その結果、蛍光体層にクラックが発生しにくくなると考えられる。
本実施形態の蛍光体塗料は、硬化性樹脂成分を含む。
本明細書において、「硬化性樹脂成分」は、(1)熱、光などの作用により硬化する性質を有する樹脂(ポリマー)成分だけでなく、(2)塗膜形成前においてはモノマーまたはオリゴマーであるが、塗膜形成後に、熱、光などの作用により高分子量化して樹脂(ポリマー)を形成可能な成分も含む。
上記に関連して、本明細書においては、ポリマー、モノマーまたはオリゴマーに加え、重合開始剤や硬化剤なども「硬化性樹脂成分」に含まれるものとする。
一例として、硬化性樹脂成分は、シラノール基(-Si-OH)を含むシリコーン樹脂を含むことが好ましい。これにより、塗膜形成時にシラノール基の縮合反応が起こり、硬化した塗膜が得られる。シラノール基(-Si-OH)を含むシリコーン樹脂の、シラノール含有量(OH重量%)は、例えば0.1質量%以上5質量%以下である。
別の例として、硬化性樹脂成分は、ビニル基含有ポリマーと、Si-H基含有シリコーンポリマとのヒドロシリル化反応により硬化するもの(付加反応タイプ)であってもよい。
一例として、硬化性樹脂成分が含む樹脂の重量平均分子量は、通常1,000以上1,000,000以下、好ましくは1,000以上500,000以下である。
硬化性樹脂成分が含む樹脂として市販品を用いる場合には、樹脂の重量平均分子量として、カタログデータを採用することができる。カタログ等から重量平均分子量が不明な場合には、例えば、ポリエチレンを標準物質としたゲルパーミエーションクロマトグラフィー(GPC)測定により求めることができる。
シリコーン樹脂の市販品としては、例えば東レ・ダウコーニング社、信越化学工業社などから入手することができる。RSN-0409、RSN-0431、RSN-0804、RSN-0805、RSN-0806、RSN-0808、RSN-0840等(東レ・ダウコーニング社製)、KF-8010、X-22-161A、KF-105、X-22-163A、X-22-169AS、KF-6001、KF-2200、X-22-164A、X-22-162C、X-22-167C、X-22-173BX等(信越化学工業社製)を挙げることができる。
例えば、硬化性樹脂成分は、(メタ)アクリレートモノマーを含むことが好ましい。(メタ)アクリレートモノマーは、単官能でも多官能でもよい。(メタ)アクリレートモノマーは、好ましくは一分子中に(メタ)アクリル構造を2以上6以下有する。
例えば、硬化性樹脂成分が(メタ)アクリレートモノマーを含む場合、ラジカル重合開始剤と併用されることが好ましい。ラジカル重合開始剤は、熱または活性光線によりラジカルを発生するものである。
エポキシ樹脂としては、ビスフェノールA型エポキシ樹脂、ハロゲン化ビスフェノールA型エポキシ樹脂、ノボラック型エポキシ樹脂、ポリグリコール型エポキシ樹脂、ビスフェノールF型エポキシ樹脂、エポキシ化油、1,6-ヘキサンジオールジグリシジルエーテル、ネオペンチルグリコールジグリシジルエーテル等が挙げられる。
硬化剤としては、通常、多価アミン、アミンアダクト、ポリアミドなどのポリアミン類及び酸無水物が挙げられる。
本実施形態の蛍光体塗料中の硬化性樹脂成分の量は、全不揮発成分中、好ましくは40vol%以上65vol%以下、より好ましくは45vol%以上60vol%以下である。
本実施形態の蛍光体塗料は、好ましくは流動性調整剤を含む。これにより、粘度の調整、塗料としての流動特性(例えばチキソトロピック性など)の調整、塗布性の調整などが可能となる場合がある。
市販の流動性調整剤として、例えば、AEROSIL 130、AEROSIL 200、AEROSIL 300、AEROSIL R-972、AEROSIL R-812、AEROSIL R-812S、AlminiumOxideC(日本アエロジル社製、AEROSILは登録商標)、カープレックスFPS-1(DSL社製、商品名)等が挙げられる。
本実施形態の蛍光体塗料が流動性調整剤を含む場合、その量は、全不揮発成分中、例えば10vol%以下、好ましくは1vol%以上5vol%以下である。体積基準ではなく質量基準では、流動性調整剤の量は、全不揮発成分中、例えば5mass%以下、好ましくは0.1mass%以上5mass%以下である。
本実施形態の蛍光体塗料は、好ましくは溶剤を含む。これにより、塗布性が良好な蛍光体塗料を得ることができる。溶剤は、水および/または有機溶剤を含む。
有機溶剤としては、炭化水素系溶剤、ケトン系溶剤、エステル系溶剤、アルコール系溶剤、アミド系溶剤、エーテル系溶剤などを挙げることができる。
本実施形態の蛍光体塗料が溶剤を含む場合、不揮発成分濃度が90質量%以下となるような量で溶剤を含むことが好ましい。ただし、不揮発成分濃度はこれに限られず、塗膜が形成可能な限りにおいて適宜量は調整すればよい。
本実施形態の蛍光体塗料は、上記以外の他成分を含んでもよい。他成分としては、防錆顔料、体質顔料、表面調整剤、ワックス、消泡剤、分散剤、紫外線吸収剤、光安定剤、酸化防止剤、レベリング剤、ベンワキ防止剤、可塑剤、帯電制御剤等が挙げられる。
前述のとおり、本実施形態の蛍光体塗料について、B型粘度計を用い、25℃、回転数20rpmで測定される粘度は、60dPa・s以上450dPa・s以下である。粘度は、好ましくは80dPs・s以上350dPa・s以下、より好ましくは90dPs・s以上320dPa・s以下である。このような粘度とすることで、特に、スクリーン印刷法により、適度な厚みの蛍光体層を形成することができる。
本実施形態の蛍光体塗料は、1液型であっても、2液以上の多液型であってもよい。具体的には、本実施形態の膜形成用樹脂組成物は、必要な成分の全てが均一に混合または分散された1液型の組成物として供給されることができる。また、本実施形態の膜形成用樹脂組成物は、一部の成分を含むA液と、残りの成分を含むB液との2液型(2液のキット)として供給されてもよい。
塗装に供する前の保存安定性などの観点で、蛍光体塗料を多液型とすることが好ましい場合がある。
本実施形態の蛍光体塗料が多液型である場合、塗膜を形成する直前に、各液を均一に混合して塗装用の塗料を得る。この塗装用の塗料の粘度が60dPa・s以上450dPa・s以下であるようにする。
上記の蛍光体塗料を用いて、蛍光体粒子を含む塗膜を形成することができる。
また、上記の蛍光体塗料を用いて、蛍光体粒子を含む塗膜を備える蛍光体基板を製造することができる。
さらに、上記の蛍光体塗料を用いて、絶縁基板と、上記の蛍光体塗料により絶縁基板の片面側に設けられた塗膜と、その塗膜における絶縁基板と反対側の面に設置された発光素子(LED素子等)と、を備える照明装置を製造することができる。
図1の照明装置においては、絶縁基板20の一方の面に蛍光塗膜26が設けられている。絶縁基板20と蛍光塗膜26との間には、絶縁基板20の側から順に、第一銅箔22および白色層24が設けられている。第一銅箔22の一部はエッチングにより除去されており、銅回路(銅配線)として機能する。
蛍光体塗料の発光効率を高める観点から、表面実装型LED素子28の下部には、白色層32(より具体的には白色樹脂層32)が設けられることが好ましい。これにより、光が抜ける(透過する)ことが抑えられる。また、白色層32と蛍光塗膜26の界面において、蛍光塗膜26からの入光の少なくとも一部は反射する。
図1の照明装置は、複数の表面実装型LED素子28を備えることができる。
絶縁基板20の厚さは、照明器具に用いることができる範囲ならば特に制限されない。例えば50μm以上1000μm以下、具体的には50μm以上500μm以下である。
白色顔料としては、酸化チタンなどの公知の顔料を挙げることができる。安定性などの観点から無機顔料が好ましい。
白色層24の厚みは、例えば10μm以上500μm以下、具体的には20μm以上400μm以下である。
塗布方法は特に限定されない。好ましい方法はスクリーン印刷法などの印刷法である。本実施形態においては、塗料組成物の粘度が60dPa・s以上450dPa・s以下であることにより、スクリーン印刷法を適用することで適度な厚みで均一な蛍光塗膜26を設けることができる。もちろん、塗布方法は他の方法であってもよく、例えば塗料分野で知られている各種コーターを用いて塗料組成物を塗布してもよい。
塗布後に、乾燥処理や、硬化処理を行うことが好ましい。乾燥処理の条件は、例えば60℃以上100℃以下で15分以上60分以下である。硬化処理の条件は、例えば100℃以上200℃以下で30分以上240分以下である。
塗料組成物中の蛍光体粒子の含有率が25vol%以上、好ましくは30vol%以上、より好ましくは35vol%以上であることにより、蛍光塗膜26の厚みが150μm以下であっても、表面実装型LED素子28から発せられた光を十分に蛍光に変換することができ、また、表面実装型LED素子28から発せられた光が蛍光体層を素通りしにくい。
リフレクタを備えない発光素子を用いることで、LEDチップからの光が横方向や下方向に漏れ出る。そして、その漏れ出た光が蛍光塗膜26のαで示した部分に当たり、αの部分が発光する。これにより、グレアや多重影の問題が一層軽減される。
図2Bにおいて、図2Aと同一の要素には同一の符号が付されている。図2Bの発光素子では、筐体(リフレクタ)は用いられない。図示されるように半導体発光素子100をマウントした後、所望の型を用いた型成形により封止部材110を形成することができる。または、予め所望の形状に成形した封止部材110を用意しておき、これを、半導体発光素子100を覆うように基板102に接着させてもよい。
以下を準備した。
(蛍光体粒子)
・CASN-1:デンカ社製のCASN系蛍光体、品番RE-650YMDB、D50=15.7μm
・CASN-2:デンカ社製のCASN系蛍光体、品番RE-Sample 650SD4、D50=3.2μm
・YAG蛍光体(比較例2で使用):D50=8.5μm
(1)超音波による分散処理
蛍光体粒子30mgを、0.2%質量に調整したヘキサメタリン酸ナトリウム水溶液100mLに均一に分散させた分散液を、底面が半径2.75cmの円柱状容器に入れた。そして、超音波ホモジナイザ(日本精機製作所社製、US-150E)の半径10mmの円柱状チップを、1.0cm以上分散液に浸し、周波数19.5kHz、出力150Wで3分間超音波を照射した。
(2)粒径分布の測定
上記(1)のように準備した分散液を、レーザー回折散乱式粒度分布測定装置(マイクロトラックベル社製、MT3300EXII)を用いて測定し、粒径分布を求めた。また、粒径分布のデータからD50を求めた。
東レ・ダウコーニング社のシリコーンレジン「RSN-0805」(シラノール基含有、シラノール含有量(OH重量)1%、二酸化珪素含有量48重量%、フェニル:メチル比=1.1:1、重量平均分子量200~300×103、キシレン含有、樹脂固形分50重量%)
日本アエロジル社のフュームドシリカ AEROSIL 200
ブチルカルビトール
後掲の表に記載の成分のうち、まず、硬化性樹脂成分(シリコーンレジン)と溶剤とを混合して均一な溶液を得た。
その後、その溶液に蛍光体粒子および流動性調整剤(実施例3のみ)を投入し、均一に混合・分散して塗料組成物を得た。
得られた塗料組成物については、B型粘度計の4号ローターを用い、25℃、回転数20rpmの条件で粘度を測定した。
上記で調整した塗料組成物などを用い、図1で説明した構造の照明装置(複数個のCSPが、一定間隔をあけて、蛍光体層の上に整列したもの)を作製した。製造手順を以下に簡単に示す。
(1)絶縁基板の材料として、両面銅箔を張り合わせた利昌工業社製のボンディングシートCS-3305Aを準備した。これの銅箔をエッチングして第一銅箔に銅回路を形成するなどした。
(2)第一銅箔の上に、白色塗料(シリコーンバインダーに酸化チタン/アルミナを50vol%で混錬したもの)を用いて、40μm厚の白色層を形成した。
(3)白色層の上に、上記の蛍光体塗料を、メッシュ数が86のスクリーンを用いたスクリーン印刷法により印刷(膜形成)し、80℃で30分プレキュアし、その後、180℃で60分ポストキュア(本硬化)した。これにより蛍光体層を形成した。この際の蛍光体層の厚みは50μm狙いとした。
(4)白色層および蛍光体層の一部を穴開け加工してはんだ用の孔を設けた。そして、表面実装型LED素子である市販のCSP(WICOP SZ8-Y15-WW-C8、ソウル半導体社製、リフレクタ無し品、色温度2200~2300K)と、第一銅箔(銅回路)とを、はんだにより電気的に接続した。
上記(3)において、
・印刷した蛍光体塗料がプレキュアの前に流動することが無く、膜厚45~55μmの均一な蛍光体層が形成できた場合を印刷性良好(○)、
・印刷した蛍光体塗料がプレキュアの前にやや流動するものの、膜厚45~55μmの均一な蛍光体層が形成できた場合を印刷性普通(△)
・十分な膜厚の蛍光体層が形成できなかったり、膜にムラが発生したりした場合を印刷性不良(×)
と評価した。
上記(3)で形成された蛍光体層の外観を観察した。後掲の表2には、実用上問題となりうる異常が見られなかった場合を「異常なし」と記載し、実用上問題となりうる異常が見られた場合、その異常の内容を記載した。
上記の蛍光体層の外観評価で「異常なし」であったものについて、以下表1の項目の試験を行った。表1のすべての項目で合格基準を満たしたものを、表2で「合格」と記載した。
上記で作製した照明装置に電流を流し、照明装置を発光させた。照明装置から発せられる光の色温度を、大塚電子株式会社製の全光束測定システム(積分球を備える装置)を用いて測定した。測定された色温度が2000~2100Kであり、CSPそのものの色温度(2200~2300K)から少なくとも100K以上色温度が変換された場合を、色温度変換性が良好(○)と評価した。一方、測定された色温度が2100~2200Kであり、色温度の変換が100K以内にとどまった場合を、色温度変換性が不十分(×)と評価した。
なお、蛍光体層の性状に異常があった比較例2においては、この評価は行わなかった。
22 第一銅箔
22B 第二銅箔
24 白色層
26 蛍光塗膜
28 表面実装型LED素子
30 はんだ
32 白色層(白色樹脂層)
100 半導体発光素子
102 基板
104 リフレクタ(筐体)
108 パッケージ状部
110 封止部材
112 配線
Claims (18)
- 蛍光体粒子と、硬化性樹脂成分と、を含む蛍光体塗料であって、
B型粘度計を用い、25℃、回転数20rpmで測定される粘度が60dPa・s以上450dPa・s以下である蛍光体塗料。 - 請求項1に記載の蛍光体塗料であって、
前記硬化性樹脂成分は、熱硬化性樹脂成分を含む蛍光体塗料。 - 請求項1または2に記載の蛍光体塗料であって、
前記硬化性樹脂成分は、シリコーン樹脂を含む蛍光体塗料。 - 請求項1から3のいずれか1項に記載の蛍光体塗料であって、
前記硬化性樹脂成分は、フェニル基およびメチル基を有するシリコーン樹脂を含む蛍光体塗料。 - 請求項1から4に記載の蛍光体塗料であって、
前記硬化性樹脂成分は、シラノール基を含むシリコーン樹脂を含む蛍光体塗料。 - 請求項1から5のいずれか1項に記載の蛍光体塗料であって、
前記蛍光体粒子のメジアン径D50は1μm以上20μm以下である蛍光体塗料。 - 請求項1から6のいずれか1項に記載の蛍光体塗料であって、
前記蛍光体粒子の粒径分布曲線において、2以上の極大が認められる蛍光体塗料。 - 請求項7に記載の蛍光体塗料であって、
前記蛍光体粒子の粒径分布曲線において、粒径1μm以上6μm以下の領域と、粒径10μm以上25μm以下の領域の両方に極大が認められる蛍光体塗料。 - 請求項1から8のいずれか1項に記載の蛍光体塗料であって、
前記蛍光体粒子が、CASN系蛍光体、SCASN系蛍光体、La3Si6N11系蛍光体、Sr2Si5N8系蛍光体、Ba2Si5N8系蛍光体、α型サイアロン系蛍光体、β型サイアロン系蛍光体、LuAG系蛍光体およびYAG系蛍光体からなる群より選ばれる1または2以上を含む蛍光体塗料。 - 請求項1から9のいずれか1項に記載の蛍光体塗料であって、
流動性調整剤を含む蛍光体塗料。 - 請求項1から10のいずれか1項に記載の蛍光体塗料であって、
さらに溶剤を含む蛍光体塗料。 - 請求項11に記載の蛍光体塗料であって、
前記溶剤は、芳香族炭化水素溶剤を含む蛍光体塗料。 - 請求項1~12のいずれか1項に記載の蛍光体塗料により形成された塗膜。
- 請求項13に記載の塗膜であって、
厚みが150μm以下である塗膜。 - 請求項13または14に記載の塗膜を備える蛍光体基板。
- 絶縁基板と、請求項1~12のいずれか1項に記載の蛍光体塗料により前記絶縁基板の片面側に設けられた塗膜と、前記塗膜における前記絶縁基板と反対側の面に設置された発光素子と、を備える照明装置。
- 請求項16に記載の照明装置であって、
複数の前記発光素子が設置された照明装置。 - 請求項16または17に記載の照明装置であって、
前記発光素子はリフレクタを備えない照明装置。
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JPH1161750A (ja) * | 1997-08-21 | 1999-03-05 | Sekisui Jushi Co Ltd | 視線誘導標識体 |
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