Wavelength converting component

Patent metadata

Field	Value
Publication number	US-11466839-B2
Application number	US-201816627405-A
Country	US
Kind code	B2
Filing date	Jun 27, 2018
Priority date	Jun 30, 2017
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

The present invention relates to a manufacturing method for a wavelength converting component which is prepared from a dispersion containing a crosslinkable ceramizable polymer material having a silazane repeating unit and at least one wavelength converting material. There are further provided wavelength converting components which can be used for converting blue, violet and/or UV light into light with a longer wavelength. There is also provided a light source and a lighting unit comprising said wavelength converting components.

First claim

The invention claimed is:

1. A method of manufacturing a wavelength converting component, wherein the wavelength converting component contains at least one wavelength converting material and a matrix material, and
wherein the method comprises the following steps:
(a) providing a dispersion containing a crosslinkable ceramizable material and at least one wavelength converting material, wherein the crosslinkable ceramizable material is a polymer containing a silazane repeating unit M 1 ;
(b-1) precuring said dispersion at a first temperature of ≥150 to ≤250° C.; and
(b-2) curing said precured dispersion at a second temperature of >300 to ≤500° C. to obtain a wavelength converting component;

wherein the precuring in step (b-1) is carried out in a mold or on a plate and the precured dispersion is removed from the mold or plate before the curing in step (b-2) takes place; and
wherein the curing in step (b-2) is carried out for ≥1 min to ≤24 h.

2. The method according to claim 1 , wherein the silazane repeating unit M 1 is represented by formula (I):
-[—SiR 1 R 2 —NR 3 —]-  (I)

wherein R 1 , R 2 and R 3 are independently from each other hydrogen or alkyl.

3. The method according to claim 2 , wherein R 1 , R 2 and R 3 in formula (I) are independently from each other selected from the group consisting of hydrogen, straight-chain alkyl having 1 to 12 carbon atoms, branched-chain alkyl having 3 to 12 carbon atoms and cycloalkyl having 3 to 12 carbon atoms.

4. The method according to claim 2 , wherein the polymer contains a further silazane repeating unit M 2 , wherein M 2 is represented by formula (II):
-[—SiR 4 R 5 —NR 6 —]-  (II)

wherein R 4 , R 5 and R 6 are independently from each other hydrogen or alkyl; and
wherein M 2 is different from M 1 .

5. The method according to claim 4 , wherein R 4 , R 5 and R 6 in formula (II) are independently from each other selected from the group consisting of hydrogen, straight-chain alkyl having 1 to 12 carbon atoms, branched-chain alkyl having 3 to 12 carbon atoms and cycloalkyl having 3 to 12 carbon atoms.

6. The method according to claim 2 , wherein the polymer contains a further repeating unit M 3 , wherein M 3 is represented by formula (III):
-[—SiR 7 R 8 —[O—SiR 7 R 8 —] a —NR 9 —]-  (III)

wherein
R 7 , R 8 , R 9 are independently from each other hydrogen or alkyl; and
a is an integer from 1 to 60.

7. The method according to claim 6 , wherein R 7 , R 8 and R 9 in formula (III) are independently from each other selected from the group consisting of hydrogen, straight-chain alkyl having 1 to 12 carbon atoms, branched-chain alkyl having 3 to 12 carbon atoms and cycloalkyl having 3 to 12 carbon atoms.

8. The method according to claim 1 , wherein the at least one wavelength converting material is selected from phosphors or converters based on semiconductor nanoparticles.

9. A wavelength converting component obtained by the method according to claim 1 , wherein the matrix material contains Si—N bonds and wherein the matrix material has a density of ≥1.21 g/cm 3 at 25° C., and wherein the matrix material shows a weight loss of ≤0.5 weight-%, upon heating from 25 to 350° C. under air atmosphere.

10. A wavelength converting component obtained by the method according to claim 1 , wherein the matrix material contains Si—N bonds and wherein the matrix material has a density of ≥1.16 g/cm 3 at 25° C., and wherein the matrix material shows a weight loss of ≤0.5 weight-%, upon heating from 25 to 350° C. under air atmosphere.

11. A wavelength converting component obtained by the method according to claim 1 , wherein the matrix material contains Si—N bonds and wherein the matrix material has a coefficient of thermal expansion of ≤150 ppm/K in a temperature range from 25 to 80° C., and wherein the matrix material shows a weight loss of ≤0.5 weight-%, upon heating from 25 to 350° C. under air atmosphere.

12. A light source comprising a primary light source and a wavelength converting component according to claim 10 .

13. A lighting unit which comprises at least one light source according to claim 12 .

14. A method for the conversion of blue, violet and/or UV light from a primary light source into light with a longer wavelength comprising passing the light through a wavelength converting component of claim 9 .

15. A method for the conversion of blue, violet and/or UV light from a primary light source into light with a longer wavelength, comprising passing the light through a wavelength converting component of claim 10 .

16. A method for the conversion of blue, violet and/or UV light from a primary light source into light with a longer wavelength, comprising passing the light through a wavelength converting component of claim 11 .

17. The lighting unit according to claim 13 , which is a lighting unit for a projector or an automobile.

18. The method according to claim 1 , wherein the mold is a PTFE mold or a PVDF mold and the plate is a PTFE plate or a PVDF plate.

19. The method according to claim 1 , wherein said first temperature is ≥150 to ≤250° C., and said second temperature of >305 to ≤500° C.

20. The method according to claim 1 , wherein the precuring in step (b-1) is carried out for a time period of ≥1 min to ≤10 h.

21. The method according to claim 1 , wherein the precuring in step (b-1) is carried out for a time period of ≥1 hr to ≤10 h and the curing in step (b-2) is carried out for ≥1 hr to ≤24 h.

22. A light source comprising a primary light source and a wavelength converting component according to claim 11 .

23. A lighting unit which comprises at least one light source according to claim 22 .

24. The lighting unit according to claim 23 , which is a lighting unit for a projector or an automobile.

25. A light source comprising a primary light source and a wavelength converting component according to claim 9 .

26. A lighting unit which comprises at least one light source according to claim 25 .

27. The lighting unit according to claim 26 , which is a lighting unit for a projector or an automobile.

Assignees

• Merck Patent Gmbh

Inventors

• Grottenmueller Ralf
• Casas Garcia-Minguillan Abraham
• Kita Fumio
• Benker Andreas
• Koehler Ingo

Classifications

• F21S43/14

  Light emitting diodes [LED] · CPC title

• G03B21/204

  using secondary light emission, e.g. luminescence or fluorescence (using different colours G03B33/00; if related to video signals H04N9/3197) · CPC title

• F21S41/141

  Light emitting diodes [LED] · CPC title

• F21S41/176

  Light sources where the light is generated by photoluminescent material spaced from a primary light generating element · CPC title

• C08G77/62

  Nitrogen atoms · CPC title