Phosphor and manufacturing method for the same, and light source

• US 20090085010A1
• Filed: 10/01/2008
• Published: 04/02/2009
• Est. Priority Date: 07/28/2004
• Status: Abandoned Application

• Current Assignee: Dowa Electronics Materials Co. Ltd. (DOWA Holdings Company Limited), Nichia Corporation
• Original Assignee: Dowa Electronics Materials Co. Ltd. (DOWA Holdings Company Limited), Nichia Corporation
• Inventors: Gotoh, Masahiro, Nagatomi, Akira, Yamashita, Shuji, Sakane, Kenji
• Application Number:
  US12/285,295
• Publication Number:
  US 20090085010A1
• Time in Patent Office: Days
• US Class Current: 252/301.40F
• CPC Class Codes: C09K 11/0883 Arsenides; Nitrides; Phosphides
• CPC Class Codes: C09K 11/77348 Silicon Aluminium Nitrides or Silicon Aluminium Oxynitrides
• CPC Class Codes: H05B 33/14 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

Abstract

To provide a phosphor having an emission characteristic such that a peak wavelength of light emission is in a range from 580 to 680 nm, and having a high emission intensity, and having a flat excitation band with high efficiency for excitation light in a broad wavelength range from ultraviolet to visible light (wavelength range from 250 nm to 550 nm). For example, Ca₃N₂(2N), AlN(3N), Si₃N₄(3N), Eu₂O₃(3N) are prepared, and after weighing and mixing a predetermined amount of each raw material, raw materials are fired at 1500° C. for 6 hours, thus obtaining the phosphor including a product phase expressed by a composition formula CaAlSiN₃:Eu and having an X-ray diffraction pattern satisfying a predetermined pattern.

Claims

1. A light source, using phosphor manufactured by a manufacturing method of a phosphor, with the product phase expressed by a composition formula MADOoNn:

Z, where element M is at least one or more kind of element having bivalent valency, element A is at least one or more kind of element having tervalent valency, element D is at least one or more kind of element selected from the elements having tetravalent valency, O is oxygen, N is nitrogen, and element Z is at least one or more kind of element selected from rare earth elements or transitional metal elements, satisfying n=3−

2/3o, o+n>

8/3, said manufacturing method comprising;

obtaining a mixture by weighing and mixing raw material powders of this phosphor under an inert atmosphere;

maintaining and firing the mixture for 0.5 hours or more at 1000°

C. or more to obtain a fired product; and

pulverizing the obtained fired product to obtain a phosphor having a prescribed average particle size,

wherein in the step of obtaining the fired product by firing the mixture, any one of nitrogen, ammonia, mixed gas of ammonia and nitrogen, or mixed gas of nitrogen and hydrogen is used as the atmosphere gas during firing, and

firing is performed while 0.01 L/min or more of the atmosphere gas in the firing furnace is ventilated.

2. A light source, using a phosphor manufactured by a manufacturing method of a phosphor, with the product phase expressed by a composition formula MADOoNn:

Z, where element M is at least one or more kind of element having bivalent valency, element A is at least one or more kind of element having tervalent valency, element D is at least one or more kind of element selected from the elements having tetravalent valency, O is oxygen, N is nitrogen, and element Z is at least one or more kind of element selected from rare earth elements or transitional metal elements, satisfying n=3−

2/3o, o+n>

8/3, said manufacturing method comprising;

obtaining a mixture by weighing and mixing raw material powders of this phosphor under an inert atmosphere;

maintaining and firing the mixture for 0.5 hours or more at 1000°

C. or more to obtain a fired product; and

pulverizing the obtained fired product to obtain a phosphor having a prescribed average particle size,

wherein in the step of obtaining the fired product by firing the mixture, any one of nitrogen, ammonia, mixed gas of ammonia and nitrogen, or mixed gas of nitrogen and hydrogen is used as the atmosphere gas during firing, and

the atmosphere gas in the firing furnace is set in a pressurized state of 0.001 MPa or more and 0.1 MPa or less.

3. A manufacturing method of a phosphor, with the product phase expressed by a composition formula MADOoNn:

Z, wherein element M is at least one or more kind of element having bivalent valency, element A is at least one or more kind of element having tervalent valency, element D is at least one or more kind of element selected from the elements having tetravalent valency, O is oxygen, N is nitrogen, and element Z is at least more than one kind of element selected from rare earth elements or transitional metal elements, satisfying n=3−

2/3o, o+n>

8/3, said manufacturing method comprising;

obtaining a mixture by weighing and mixing raw material powders of this phosphor under an inert atmosphere;

maintaining and firing the mixture for 0.5 hours or more at 1000°

C. or more to obtain a fired product; and

pulverizing the obtained fired product to obtain a phosphor having a prescribed average particle size,

wherein in the step of obtaining the fired product by firing the mixture, any one of nitrogen, ammonia, mixed gas of ammonia and nitrogen, or mixed gas of nitrogen and hydrogen is used as the atmosphere gas during firing, and

the atmosphere gas in the firing furnace is set in a pressurized state of 0.001 MPa or more and 0.1 MPa or less.

4. A manufacturing method of a phosphor, with the product phase expressed by a composition formula MADOoNn:

Z, where element M is at least one or more kind of element having bivalent valency, element A is at least one or more kind of element having tervalent valency, element D is at least one or more kind of element selected from the elements having tetravalent valency, O is oxygen, N is nitrogen, and element Z is at least one or more kind of element selected from rare earth elements or transitional metal elements, satisfying n=3−

2/3o, o+n>

8/3, said manufacturing method comprising;

obtaining a mixture by weighing and mixing raw material powders of this phosphor under an inert atmosphere;

maintaining and firing the mixture for 0.5 hours or more at 1000°

C. or more to obtain a fired product; and

pulverizing the obtained fired product to obtain a phosphor having a prescribed average particle size,

wherein in the step of obtaining the fired product by firing the mixture, any one of nitrogen, ammonia, mixed gas of ammonia and nitrogen, or mixed gas of nitrogen and hydrogen is used as the atmosphere gas during firing, and

firing is performed while 0.01 L/min or more of the atmosphere gas in the firing furnace is ventilated,

wherein

the element M is one or more kind of element having bivalent valency, indispensably including Ca;

the element A is one or more kind of element having tervalent valency, indispensably including Al;

the element D is one or more kind of element having tetravalent valency, indispensably including Si, and

the phosphor comprises a phase showing a diffraction peak with relative intensity of 10% or more in the Bragg angle (2θ

) range from 36.5°

to 37.5° and

from 40.9°

to 41.9°

, 41.9°

to 42.9°

, and 56.3°

to 57.3°

, of the X-ray diffraction pattern, when the relative intensity of the diffraction peak having a highest intensity in a powder X-ray diffraction pattern by CoKα

ray is defined as 100%.