Phosphor, preparing method for phosphor, and light emitting device

• US 9,884,991 B2
• Filed: 10/23/2014
• Issued: 02/06/2018
• Est. Priority Date: 12/26/2013
• Status: Active Grant

• Current Assignee: Alpad Corporation
• Original Assignee: CHI MEI Corporation
• Inventors: Yu, Szu-Chun, Uen, Jen-Shrong
• Primary Examiner(s): Hoban, Matthew E
• Assistant Examiner(s): EDMONDSON, LYNNE RENEE
• Application Number:
  US14/521,550
• Publication Number:
  US 20150184071A1
• Time in Patent Office: 1,202 Days
• Field of Search: 2523014 R, 313503
• CPC Class Codes: C09K 11/7769 Oxides C09K11/7768 takes precedence
• CPC Class Codes: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/8592 Applying permanent coating, e.g. protective coating
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 2933/0041 relating to wavelength conversion elements
• CPC Class Codes: H01L 33/502 Wavelength conversion materials
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

A phosphor is disclosed, including a formula of A_3-aCe_aQ_5-eE_eO₁₂. The A, the Q and the E independently comprise elements aluminum (Al), gallium (Ga), indium (In), scandium (Sc), yttrium (Y), lanthanum (La), gadolinium (Gd), terbium (Tb), lutetium (Lu), or a combination thereof. Ce is cerium. O is oxygen. 0<a≦3. 0≦e≦5. A diameter distribution span of the phosphor is less than 0.7.

Claims

1. A preparing method for a phosphor, comprising:

sintering a raw material mixture to obtain a sintered phosphor material, mixing the sintered phosphor material with an alkali metal silicate aqueous solution to obtain a phosphor mixture, grinding the phosphor mixture, and then subjecting the ground phosphor mixture containing the alkali metal silicate aqueous solution to a water-washing step to remove suspended particles, and drying the washed phosphor mixture, wherein the alkali metal silicate aqueous solution consists essentially of 1.5-2 wt % of a water glass, the water glass consists essentially of alkali metal oxide and silicon oxide, wherein a numerical value of the sintered phosphor material based on a weight unit “

g”

is substantially the same as a numerical value of the alkali metal silicate aqueous solution based on a volume unit “

ml”

, the phosphor consists essentially of a formula of A_3-aCe_aQ_5-eAl_eO₁₂, wherein the A consists essentially of yttrium (Y), lanthanum (La), gadolinium (Gd), terbium (Tb), lutetium (Lu), or a combination thereof, 0<

a≦

3, 3≦

e<

5, and a diameter distribution span of the phosphor is less than 0.7.

2. The preparing method for the phosphor according to claim 1, wherein the alkali metal oxide comprises an alkali metal of Na, K, or a combination thereof.

3. The preparing method for the phosphor according to claim 1, wherein the alkali metal oxide comprises Na₂O, K₂O, or a combination thereof.

4. The preparing method for the phosphor according to claim 1, wherein the water glass have a molecular formula of Na₂O.nSiO₂ or a molecular formula of K₂O.nSiO₂, the coefficient of n is 1.5˜

4.0.

5. The preparing method for the phosphor according to claim 4, wherein in the molecular formula of Na₂O.nSiO₂ or the molecular formula of K₂O.nSiO₂, the coefficient of n is 2.0˜

3.5.

6. The preparing method for the phosphor according to claim 1, wherein 0.03≦

a≦

0.1.

7. The preparing method for the phosphor according to claim 1, wherein as a median diameter (D50) of the phosphor is larger than 13 μ

m, a content of the phosphor larger than 20 μ

m is less than 5% of volume of the phosphor.

8. The preparing method for the phosphor according to claim 1, wherein as a median diameter (D50) of the phosphor is larger than 13 μ

m, a content of the phosphor larger than 20 μ

m is less than 5% and more than 3% of volume of the phosphor.

9. The preparing method for the phosphor according to claim 1, wherein as a median diameter (D50) of the phosphor is larger than 13 μ

m, a content of the phosphor in 10˜

20 μ

m is more than 80% of volume of the phosphor.

10. The preparing method for the phosphor according to claim 1, wherein as a median diameter (D50) of the phosphor is larger than 13 μ

m, a content of the phosphor in 10˜

20 μ

m is more than 80% and less than 90% of volume of the phosphor.

11. The preparing method for the phosphor according to claim 1, wherein as a median diameter (D50) of the phosphor is larger than 13 μ

m, a content of the phosphor less than 10 μ

m is less than 15% of volume of the phosphor.

12. The preparing method for the phosphor according to claim 1, wherein as a median diameter (D50) of the phosphor is larger than 13 μ

m, a content of the phosphor less than 10 μ

m is less than 15% and more than 10% of volume of the phosphor.

13. The preparing method for the phosphor according to claim 1, as a median diameter (D50) of the phosphor is less than 13 μ

m, a content of the phosphor in 10˜

15 μ

m is more than 50% of volume of the phosphor.

14. The preparing method for the phosphor according to claim 1, wherein the alkali metal silicate aqueous solution consists essentially of a water solvent and 1.5-2 wt % of the water glass as a solute dissolved in the water solvent.

15. The preparing method for the phosphor according to claim 13, wherein the water glass have a molecular formula of Na₂O.nSiO₂ or a molecular formula of K₂O.nSiO₂, the coefficient of n is 1.5˜

4.0.

16. The preparing method for the phosphor according to claim 15, wherein in the molecular formula of Na₂O.nSiO₂ or the molecular formula of K₂O.nSiO₂, the coefficient of n is 2.0˜

3.5.

17. The preparing method for the phosphor according to claim 13, wherein 0.03≦

a≦

0.1.

18. The preparing method for the phosphor according to claim 13, wherein the alkali metal silicate aqueous solution consists essentially of a water solvent and 1.5-2 wt % of the water glass as a solute dissolved in the water solvent.