LED DEVICE MANUFACTURING METHOD AND FLUORESCENT MATERIAL-DISPERSED SOLUTION USED IN SAME

• US 20150004728A1
• Filed: 10/05/2012
• Published: 01/01/2015
• Est. Priority Date: 10/07/2011
• Status: Active Grant

• Current Assignee: Konica Minolta Inc.
• Original Assignee: Konica Minolta Inc.
• Inventors: Taguchi, Yoshihito
• Granted Patent: US 9,318,646 B2
• Time in Patent Office: Days
• US Class Current: 438/29
• CPC Class Codes: C09K 11/025 non-luminescent particle coatings or suspension media
• CPC Class Codes: C09K 11/7774 Aluminates
• CPC Class Codes: H01L 2224/16225 the item being non-metallic, e.g. insulating substrate with or without metallisation
• CPC Class Codes: H01L 2924/16195 Flat cap [not enclosing an internal cavity]
• CPC Class Codes: H01L 2933/0025 relating to coatings
• CPC Class Codes: H01L 2933/0041 relating to wavelength conversion elements
• CPC Class Codes: H01L 33/005 Processes
• CPC Class Codes: H01L 33/505 characterised by the shape, e.g. plate or foil
• CPC Class Codes: H01L 33/507 the elements being in intimate contact with parts other than the semiconductor body or integrated with parts other than the semiconductor body

Abstract

The present invention addresses the problem of providing an LED device having no color unevenness in light emission. In order to solve the problem, this LED device manufacturing method includes: a step of providing an LED chip-mounted package; a step of film-forming a fluorescent material layer by applying a fluorescent material-dispersed solution to a emission surface of the LED chip, said fluorescent material-dispersed solution containing a solvent, a fluorescent material, clay minerals and porous inorganic particles, and by drying the fluorescent material-dispersed solution; and a step of film-forming a wavelength conversion section by applying, to the fluorescent material layer, a precursor solution having a precursor of a light transmissive ceramic dispersed in a solvent, and by firing the layer, said wavelength conversion section being composed of a light transmissive ceramic layer having the fluorescent material, the clay minerals and the porous inorganic particles dispersed therein.

Claims

1. A method for manufacturing an LED device having an LED chip and a wavelength conversion part to convert light emitted from the LED chip to light having a wavelength different from a wavelength of the light emitted from the LED chip, the method comprising:

providing an LED chip package including a package and an LED chip disposed on the package, the LED chip having an emission surface;

applying on the emission surface of the LED chip a phosphor dispersion liquid containing a solvent, a phosphor, a clay mineral and porous inorganic particles, the phosphor, the clay mineral and the porous inorganic particles being dispersed in the solvent, followed by drying to form a phosphor layer; and

applying on the phosphor layer a precursor solution in which a light transmissive ceramic precursor is dispersed in a solvent, followed by calcination to form a wavelength conversion part made of a light transmissive ceramic layer in which the phosphor, the clay mineral and the porous inorganic particles are dispersed.

2. The manufacturing method according to claim 1, wherein a specific surface area of the porous inorganic particles is 200 m²/g or more.

3. The manufacturing method according to claim 1, wherein an average particle size of primary particles of the porous inorganic particles is 0.001 to 50 μ

m.

4. The manufacturing method according to claim 1, wherein in the light transmissive ceramic layer, an amount of the porous inorganic particles is 0.5 to 50 wt %, and an amount of the clay mineral is 0.5 wt % to 20 wt %.

5. A method for manufacturing an LED device having an LED chip and a wavelength conversion part to convert light emitted from the LED chip to light having a wavelength different from a wavelength of the light emitted from the LED chip, the method comprising:

applying on a light transmissive substrate a phosphor dispersion liquid containing a solvent, a phosphor, a clay mineral and porous inorganic particles, the phosphor, the clay mineral and the porous inorganic particles being dispersed in the solvent, followed by drying to form a phosphor layer;

applying on the phosphor layer a precursor solution in which a light transmissive ceramic precursor is dispersed in a solvent, followed by calcination to form a wavelength conversion part made of a light transmissive ceramic layer in which the phosphor, the clay mineral and the porous inorganic particles are dispersed; and

installing the light transmissive substrate on which the wavelength conversion part is formed in an LED chip package including a package and an LED chip having an emission surface and disposed on the package.

6. The manufacturing method according to claim 5, wherein a specific surface area of the porous inorganic particles is 200 m²/g or more.

7. The manufacturing method according to claim 5, wherein an average particle size of primary particles of the porous inorganic particles is 0.001 to 50 μ

m.

8. The manufacturing method according to claim 5, wherein in the light transmissive ceramic layer, an amount of the porous inorganic particles is 0.5 to 50 wt %, and an amount of the clay mineral is 0.5 to 20 wt %.

9. A method for manufacturing an LED device having an LED chip and a wavelength conversion part to convert light emitted from the LED chip to light having a wavelength different from a wavelength of the light emitted from the LED chip, the method comprising:

providing an LED chip package including a package and an LED chip disposed on the package, the LED chip having an emission surface; and

applying on the emission surface of the LED chip a phosphor dispersion liquid containing a solvent, a phosphor, a clay mineral, porous inorganic particles and a light transmissive ceramic precursor, the phosphor, the clay mineral, the porous inorganic particles and the light transmissive ceramic precursor being dispersed in the solvent, followed by calcination to form a wavelength conversion part made of a light transmissive ceramic layer in which the phosphor, the clay mineral and the porous inorganic particles are dispersed.

10. The manufacturing method according to claim 9, wherein a specific surface area of the porous inorganic particles is 200 m²/g or more.

11. The manufacturing method according to claim 9, wherein an average particle size of primary particles of the porous inorganic particles is 0.001 to 50 μ

m.

12. The manufacturing method according to claim 9, wherein in the light transmissive ceramic layer, an amount of the porous inorganic particles is 0.5 to 50 wt %, and an amount of the clay mineral is 0.5 to 20 wt %.

13. A method for manufacturing an LED device having an LED chip and a wavelength conversion part to convert light emitted from the LED chip to light having a wavelength different from a wavelength of the light emitted from the LED chip, the method comprising:

applying on a light transmissive substrate a phosphor dispersion liquid containing a solvent, phosphor, a clay mineral, porous inorganic particles and a light transmissive ceramic precursor, the phosphor, the clay mineral, the porous inorganic particles and the light transmissive ceramic precursor being dispersed in the solvent, followed by calcination to form a wavelength conversion part made of a light transmissive ceramic layer in which the phosphor, the clay mineral and the porous inorganic particles are dispersed; and

installing the light transmissive substrate on which the wavelength conversion part is formed in an LED chip package including a package and an LED chip having an emission surface and disposed on the package.

14. The manufacturing method according to claim 13, wherein a specific surface area of the porous inorganic particles is 200 m²/g or more.

15. The manufacturing method according to claim 13, wherein an average particle size of primary particles of the porous inorganic particles is 0.001 to 50 μ

m.

16. The manufacturing method according to claim 13, wherein in the light transmissive ceramic layer, an amount of the porous inorganic particles is 0.5 to 50 wt %, and an amount of the clay mineral is 0.5 to 20 wt %.

17. A phosphor dispersion liquid comprising a solvent, a phosphor, a clay mineral, and porous inorganic particles, the phosphor, the clay mineral and the porous inorganic particles being dispersed in the solvent.

18. The phosphor dispersion liquid according to claim 17, wherein an amount of the porous inorganic particles is 0.1 to 40 wt %, and an amount of the clay mineral is 0.05 to 18 wt %.

19. A phosphor dispersion liquid comprising a solvent, a phosphor, a clay mineral, porous inorganic particles, and a light transmissive ceramic precursor, the phosphor, the clay mineral, the porous inorganic particles and the light transmissive ceramic precursor being dispersed in the solvent.

20. The phosphor dispersion liquid according to claim 19, wherein an amount of the porous inorganic particles is 0.1 to 40 wt %, and an amount of the clay mineral is 0.05 to 18 wt %.