Green Design

Development of Advanced LED Phosphors by Spray-based Processes for Solid-State Lighting

Cabot’s spray-based process for producing phosphor powders is able to improve the brightness of the powder itself by increasing the activator (the species that emits the light) concentration without adverse quenching effects compared to conventional synthesis. This will allow less phosphor powder to be used, and will decrease the cost of the light source; thus lowering the barrier of entry to the lighting market. The process also allows for chemical flexibility of the phosphor particles, which may result in tunable emission spectra and so light sources with improved color rendering. Another benefit of Cabot’s process is the resulting spherical morphology of the particles. Less light scattering results when spherical particles are used in the phosphor layer compared to when conventional, irregular shaped phosphor particles are used. This spherical morphology will result in better light extraction and so an improvement of efficiency in the overall device.

Cabot has produced a number of different compositions in a spherical morphology that may be useful for solid state lights, as well as demonstrated processes that are able to produce particles from 10 nanometers to 3 micrometers. Towards the end of the project Cabot demonstrated that the process produces YAG:Ce powder that has both higher internal quantum efficiency (0.6 compared to 0.45) and external quantum efficiency (0.85 compared to 0.6) than the commercial standard. However, these highly bright materials were only produced in research and development quantities, not in a reproducible manner at a commercial scale.

This work was done by Cabot Corp., Boston, MA. DE-FC26-04NT42276

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