Method of manufacturing fluorescent-material-containing member

Patent metadata

Field	Value
Publication number	US-10400993-B2
Application number	US-201715440292-A
Country	US
Kind code	B2
Filing date	Feb 23, 2017
Priority date	Feb 24, 2016
Publication date	Sep 3, 2019
Grant date	Sep 3, 2019

Abstract

A method of manufacturing a fluorescent-material-containing member includes: providing a fluorescent member including a fluorescent material, the fluorescent member having a first main surface side including a plurality of projections; disposing a powder of a light-reflective member between the projections of the fluorescent member; obtaining a sintered body by sintering the powder of the light-reflective member, and removing part of the sintered body from at least one of a first main surface side and a second main surface side of the fluorescent member to obtain the fluorescent-material-containing member including a first surface arranged on the first main surface side has and defined by the fluorescent member and the light-reflective member, and a second surface arranged on the second main surface side has and defined by the fluorescent member and the light-reflective member or defined solely by the fluorescent member.

First claim

What is claimed is:

1. A method of manufacturing a fluorescent-material-containing member, the method comprising:
providing a fluorescent member including a fluorescent material, the fluorescent member having a first main surface side including a plurality of projections and a second main surface side opposite to the first main surface side;
disposing a powder of a light-reflective member between the projections of the fluorescent member;
obtaining a sintered body by sintering the powder of the light-reflective member, the sintered body including the light-reflective member integrally formed with the fluorescent member; and
removing part of the sintered body from at least one of the first main surface side and the second main surface side of the fluorescent member to obtain a fluorescent-material-containing member such that
the fluorescent-material-containing member includes a first surface arranged on the first main surface side and defined by the fluorescent member and the light-reflective member, and a second surface arranged on the second main surface side and defined by the fluorescent member and the light-reflective member, or
the fluorescent-material-containing member includes the first surface arranged on the first main surface side and defined by the fluorescent member and the light-reflective member, and the second surface arranged on the second main surface side and defined solely by the fluorescent member.

2. The method of manufacturing a fluorescent-material-containing member according to claim 1 , wherein
the removing of the part of the sintered body includes removing the part of the sintered body to obtain the second surface defined by the fluorescent member and the light-reflective member.

3. The method of manufacturing a fluorescent-material-containing member according to claim 2 , wherein
the obtaining of the sintered body includes performing spark plasma sintering or hot pressing sintering.

4. The method of manufacturing a fluorescent-material-containing member according to claim 1 , wherein
the fluorescent member includes the fluorescent material having an oxide containing aluminum, and
the light-reflective member contains aluminum oxide.

5. The method of manufacturing a fluorescent-material-containing member according to claim 4 , wherein
the fluorescent member contains aluminum oxide as a sintering agent.

6. The method of manufacturing a fluorescent-material-containing member according to claim 5 , wherein
the providing of the fluorescent member includes sintering a mixture of a powder of the fluorescent material and a powder of the sintering agent to obtain the fluorescent member having the projections on the first main surface side, and
a sintering temperature in the sintering of the powder of the light-reflective member is lower than a sintering temperature in the sintering of the mixture of the powder of the fluorescent material and the sintering agent.

7. The method of manufacturing a fluorescent-material-containing member according to claim 4 , further comprising
heat-treating the sintered body in an oxidizing atmosphere after the sintered body is obtained.

8. The method of manufacturing a fluorescent-material-containing member according to claim 1 , wherein
the providing of the fluorescent member includes:
filling a container with a powder of the fluorescent member containing the fluorescent material, and
pressing the powder of the fluorescent member with a pressing member having a plurality of depressions to form the projections of the fluorescent member, and

the obtaining of the sintered body includes sintering the fluorescent member and the light-reflective member.

9. The method of manufacturing a fluorescent-material-containing member according to claim 8 , wherein
each of the depressions of the pressing member has an opening that becomes wider as being further away from a bottom surface of a corresponding one of the depressions.

10. The method of manufacturing a fluorescent-material-containing member according to claim 1 , wherein
the providing of the fluorescent member includes forming the projections on the fluorescent member that has been sintered.

11. The method of manufacturing a fluorescent-material-containing member according to claim 10 , wherein
the forming of the projections includes forming the projections with a machining center.

12. The method for manufacturing a fluorescent-material-containing member according to claim 10 , wherein
the fluorescent member includes the fluorescent material having an oxide containing aluminum, and
the light-reflective member contains aluminum oxide.

13. The method of manufacturing a fluorescent-material-containing member according to claim 1 , the method further comprising
singulating the sintered body after the removing of the part of the sintered body so that at least one of the first surface and the second surface of the fluorescent-material-containing member obtained after the singulating of the sintered body includes the light-reflective member around the fluorescent member.

14. A method of manufacturing a fluorescent-material-containing member, the method comprising:
providing a light-reflective member having a first main surface side including a plurality of depressions and a second main surface side opposite to the first main surface side;
disposing a powder of a fluorescent member containing a fluorescent material in the depressions of the light-reflective member;
obtaining a sintered body by sintering the powder of the fluorescent member, the sintered body including the light-reflective member integrally formed with the fluorescent member; and
removing part of the sintered body from at least the second main surface side of the light-reflective member to obtain a fluorescent-material-containing member such that
the fluorescent-material-containing member includes a second surface arranged on the second main surface side and defined by the fluorescent member and the light-reflective member, and a first surface arranged on the first main surface side and defined by the fluorescent member and the light-reflective member, or
the fluorescent-material-containing member includes the second surface arranged on the second main surface side and defined by the fluorescent member and the light-reflective member, and the first surface arranged on the first main surface side and defined solely by the fluorescent member.

15. The method of manufacturing a fluorescent-material-containing member according to claim 14 , wherein
the removing of the part of the sintered body includes removing the part of the sintered body to obtain the first surface defined by the fluorescent member and the light-reflective member.

16. The method of manufacturing a fluorescent-material-containing member according to claim 15 , wherein
the providing of the light-reflective member includes:
filling a container with a powder of the light-reflective member, and
pressing the powder of the light-reflective member with a pressing member including a plurality of projections to form the depressions of the light-reflective member,

the obtaining of the sintered body includes sintering the fluorescent member and the light-reflective member.

17. The method of manufacturing a fluorescent-material-containing member according to claim 16 , wherein
the obtaining of the sintered body includes performing spark plasma sintering or hot pressing sintering.

18. The method of manufacturing a fluorescent-material-containing member according to claim 14 , wherein
the flu

Assignees

• Nichia Corp

Inventors

• Yamada Shoichi
• Wakaki Takayoshi
• Sano Masahiko

Classifications

• C09K11/0838 Primary

  Aluminates; Silicates · CPC title

• C09K11/00

  Luminescent materials, e.g. electroluminescent or chemiluminescent · CPC title

• F21K9/64

  using wavelength conversion means distinct or spaced from the light-generating element, e.g. a remote phosphor layer · CPC title

• F21V9/08

  for producing coloured light, e.g. monochromatic; for reducing intensity of light (with provision for controlling the colour F21V9/40) · CPC title

• F21K9/68

  Details of reflectors forming part of the light source · CPC title