METHOD OF STABILIZING ALPH-SIALON PHOSPHOR RAW POWDER, ALPH-SIALON PHOSPHOR COMPOSITION OBTAINED THEREFROM, AND METHOD OF MANUFACTURING ALPHA-SIALON PHOSPHOR

• US 20140191159A1
• Filed: 02/06/2013
• Published: 07/10/2014
• Est. Priority Date: 01/04/2013
• Status: Abandoned Application

• Current Assignee: Korea Institute of Machinery and Materials (Dawonsys Co., Ltd.)
• Original Assignee: Korea Institute of Machinery & Materials (Dawonsys Co., Ltd.)
• Inventors: LEE, Jae Wook, KIM, Jin Myung, PARK, Young Jo
• Application Number:
  US13/761,110
• Publication Number:
  US 20140191159A1
• Time in Patent Office: Days
• US Class Current: 252/301.4F
• CPC Class Codes: C09K 11/0883 Arsenides; Nitrides; Phosphides
• CPC Class Codes: C09K 11/77348 Silicon Aluminium Nitrides or Silicon Aluminium Oxynitrides

Abstract

Disclosed herein is a method of stabilizing alpha-sialon phosphor raw powder, including the steps of: mixing alpha-sialon phosphor raw powder including Si₃N₄, AlN, a rare-earth metal oxide and calcium nitride (Ca₃N₂) as a calcium source and having Composition Formula represented by Ca_xSi_12−m−nAl_m+nO_nN_16−n:Re_y (here, Re is an activator and is at least one selected from the group consisting of Eu, Ce, Tb, Yb, Sm and Dy, 0.3≦m≦1.0, 0.02≦y≦0.15, m=2x+3y); and heat-treating the alpha-sialon phosphor raw powder to convert the calcium source into a Ca—Al—Si—N based compound. This method is advantageous in that a reliable alpha-sialon phosphor having high photoluminescence intensity can be manufactured regardless of weather, season, environment and the like.

Claims

1. A method of stabilizing alpha-sialon phosphor raw powder, comprising the steps of:

mixing alpha-sialon phosphor raw powder including Si₃N₄, AlN, a rare-earth metal oxide and calcium nitride (Ca₃N₂) as a calcium source and having Composition Formula represented by Ca_xSi<sub>12−

m−

n</sub>Al_m+nO_nN<sub>16−

n</sub>;

Re_y (here, Re is an activator and is at least one selected from the group consisting of Eu, Ce, Tb, Yb, Sm and Dy, 0.3≦

m≦

1.0, 0.02≦

y≦

0.15, m=2x+3y); and

heat-treating the alpha-sialon phosphor raw powder to convert the calcium source into a Ca—

Al—

Si—

N based compound.

2. The method of claim 1, wherein the step of converting the calcium source into a Ca—

Al—

Si—

N based compound is performed at a temperature of 1000°

C. or more under a nitrogen atmosphere.

3. The method of claim 2, wherein the step of converting the calcium source into the Ca—

Al—

Si—

N based compound is performed at a temperature of 1000˜

1250°

C. under a nitrogen atmosphere.

4. The method of claim 1, wherein a mixing apparatus for performing the step of mixing the alpha-sialon phosphor raw powder and a heat treatment apparatus for the step of converting the calcium source into the Ca—

Al—

Si—

N based compound communicate with each other under a nitrogen atmosphere.

5. The method of claim 1, wherein the Ca—

Al—

Si—

N based compound includes CaAlSiN₃.

6. A method of manufacturing an alpha-sialon phosphor, comprising the steps of:

mixing Si₃N₄, AlN, a rare-earth metal oxide and a Ca—

Al—

Si—

N based compound to prepare Composition Formula represented by Ca_xSi<sub>12−

m−

n</sub>Al_m+nO_nN<sub>16−

n</sub>;

Re_y (here, Re is an activator and is at least one selected from the group consisting of Eu, Ce, Tb, Yb, Sm and Dy, 0.3≦

m≦

1.0, 0.02≦

y≦

0.15, m=2x+3y); and

sintering the mixture.

7. An alpha-sialon phosphor composition, comprising Si₃N₄, AlN, a rare-earth metal oxide and a Ca—

Al—

Si—

N based compound and represented by Ca_xSi<sub>12−

m−

n</sub>Al_m+nO_nN<sub>16−

n</sub>;

Re_y (here, Re is an activator and is at least one selected from the group consisting of Eu, Ce, Tb, Yb, Sm and Dy, 0.3≦

m≦

1.0, 0.02≦

y≦

0.15, m=2x+3y).