HANDBOOK ON THE PHYSICS AND CHEMISTRY OF RARE EARTHS

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HANDBOOK ON THE PHYSICS AND CHEMISTRY OF RARE EARTHS ( handbook-onphysics-and-chemistry-rare-earths )

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Rare Earth-Doped Phosphors for White LEDs Chapter 278 91 of a conventional LED with the phosphor dispersed in encapsulant. The phos- phor configuration in the latter work was not exactly the same as the so-called remote phosphor, but they indicated logically that separation of the phosphor from LED chips may improve light-conversion efficiency. Meanwhile, Leung (2014) pointed out that the increase in manufacturing cost of remote phosphor does not balance the gain of light output. He claimed that a downlight module with increased number of conventional white LED packages is cheaper than a downlight using a remote phosphor with the same output. There are many types of remote phosphor components. Typical ones are plate-shaped polycarbonate (Meneghini et al., 2013), polyethylene terephthal- ate (PET) (Huang et al., 2011a), or glass on which phosphors are applied with some binder. Phosphor-containing resins or glasses with a variety of shapes (plate, sphere, dome, etc.) have also been widely examined (Conner, 2012; Intematix, 2014; Schiel, 2012). A heat-resistant flexible fluorocarbon polymer-containing phosphor was also proposed as a remote phosphor (Huang et al., 2014). Many phosphor-containing glasses applicable to the remote-phosphor technology have also been studied. For instance, a composite glass (called “glass ceramics”) was produced by annealing a Ce-containing SiO2–Al2O3– Y2O3 glass (Fujita et al., 2008) leading to the deposition of crystals of YAG:Ce3+ phosphor. Another example is a phosphor-containing glass com- posite, which was obtained by heating a pressed mixture of glass powder and phosphors to a temperature above the glass transition temperature Tg (Fujita et al., 2013). The composite showed no degradation under 121°C, 95% relative humidity, and 2 atm (so-called highly accelerated stress test con- ditions, HAST) for 300 h. On the other hand, a silicone resin composite of the same condition showed apparent degradation. A last example is a phosphor- doped glass obtained by mixing a SiO2–Na2O–Al2O3–Ca2O glass powder with the phosphor (Tsai et al., 2013). The glass showed better stability in light output during the thermal aging test than a phosphor-mixed silicone resin. Electrophoretic deposition (EPD) is another process tested for application of phosphors on glass plates. The EPD process results in high particle densi- ties, but adhesion is usually low. To remedy this problem, a photochemical reaction was applied to the EPD process (Yum et al., 2003). A mixed solution of polyvinyl alcohol and ammonium dichromate ((NH4)2Cr2O7) was depos- ited on the phosphor layer made by EPD. Then, UV light was irradiated on it to improve the adhesion. Another way of improving the adhesion was pro- posed (Kitabatake et al., 2012). First, the surface of a phosphor powder was coated with SiO2 synthesized from TEOS. The coated phosphor was then deposited on a glass plate by EPD and a SiO2 sol was applied on the phosphor layer to fill up the space between phosphors. Finally, the plate was heated to 773 K to convert the SiO2 sol to SiO2 glass and fill up the space to improve the adhesion of phosphors.

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