# Patent

## Title
Phosphor and light-emitting equipment using phosphor

## Abstract

An object of the present invention is to provide an inorganic phosphor having fluorescence properties emitting an orange or red light which has a longer wavelength as compared with the cases of conventional sialon phosphors activated with a rare earth.
The invention relates to a design of white light-emitting diode rich in a red component and having good color-rendering properties by employing a solid solution crystal phase phosphor which uses as a host crystal an inorganic compound having the same crystal structure as that of a CaSiAlN3 crystal phase and to which M (wherein M is one or two or more elements selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb) is added as an emission center.

## Background
FIELD OF THE INVENTION
The present invention relates to a phosphor mainly composed of an inorganic compound and applications thereof. More specifically, the applications relate to light-emitting equipments such as a lighting equipment and an image display unit as well as a pigment and an ultraviolet absorbent, which utilize a property possessed by the phosphor, i.e., a characteristic of emitting fluorescence having a long wavelength of 570 nm or longer.
BACKGROUND ART
Phosphors are used for a vacuum fluorescent display (VFD), afield emission display (FED), a plasma display panel (PDP), a cathode ray tube (CRT), a white light-emitting diode (LED), and the like. In all these applications, it is necessary to provide energy for exciting the phosphors in order to cause emission from the phosphors. The phosphors are excited by an excitation source having a high energy, such as a vacuum ultraviolet ray, an ultraviolet ray, an electron beam, or a blue light to emit a visible light. However, as a result of exposure of the phosphors to the above excitation source, there arises a problem of decrease of luminance of the phosphors and hence a phosphor exhibiting no decrease of luminance has been desired. Therefore, a sialon phosphor has been proposed as a phosphor exhibiting little decrease of luminance instead of conventional silicate phosphors, phosphate phosphors, aluminate phosphors, sulfide phosphors, and the like.
The sialon phosphor is produced by the production process outlined below. First, silicon nitride (Si3N4), aluminum nitride (AlN), calcium carbonate (CaCO3), and europium oxide (Eu2O3) are mixed in a predetermined molar ratio and the mixture is held at 1700° C. for 1 hour in nitrogen at 1 atm (0.1 MPa) and is baked by a hot pressing process to produce the phosphor (e.g., cf. Patent Literature 1). The α-sialon activated with Eu obtained by the process is reported to be a phosphor which is excited by a blue light of 450 to 500 nm to emit a yellow light of 550 to 600 nm. However, in the applications of a white LED and a plasma display using an ultraviolet LED as an excitation source, phosphors emitting lights exhibiting not only yellow color but also orange color and red color have been desired. Moreover, in a white LED using a blue LED as an excitation source, phosphors emitting lights exhibiting orange color and red color have been desired in order to improve color-rendering properties.
As a phosphor emitting a light of red color, an inorganic substance (Ba2-xEuxSi5N8: x=0.14 to 1.16) obtained by activating a Ba2Si5N8 crystal phase with Eu has been reported in an academic literature (cf. Non-Patent Literature 1) prior to the present application. Furthermore, in Chapter 2 of a publication “On new rare-earth doped M-Si—Al—O—N materials” (cf. Non-Patent Literature 2), a phosphor using a ternary nitride of an alkali metal and silicon having various compositions, MxSiyNz (M=Ca, Sr, Ba, Zn; x, y, and z represent various values) as a host has been reported. Similarly, MxSiyNz:Eu (M=Ca, Sr, Ba, Zn; z=2/3x+4/3y) has been reported in U.S. Pat. No. 6,582,663 (Patent Literature 2).
As other sialon, nitride or oxynitride phosphors, there are known in JP-A-2003-206431 (Patent Literature 3) phosphors using MSi3N5, M2Si4N7, M4Si6N11, M9Si11N23, M16Si15O6N32, M13 Si18Al12O18N36, MSi5Al2ON9, and M3Si5AlON10 (wherein M represents Ba, Ca, Sr or a rare earth element) as host crystals, which are activated with Eu or Ce. Among them, phosphors emitting a light of red color have been also reported. Moreover, LED lighting units using these phosphors are known. Furthermore, JP-A-2002-322474 (Patent Literature 4) has reported a phosphor wherein an Sr2Si5N8 or SrSi7N10 crystal phase is activated with Ce.
In JP-A-2003-321675 (Patent Literature 5), there is a description of LxMyN(2/3x+4/3y):Z (L is a divalent element such as Ca, Sr, or Ba, M is a tetravalent element such as Si or Ge, and Z is an activator such as Eu) phosphor and it describes that addition of a minute amount of Al exhibits an effect of suppressing afterglow. Moreover, a slightly reddish warm color white emitting apparatus is known, wherein the phosphor and a blue LED are combined. Furthermore, JP-A-2003-277746 (Patent Literature 6) reports phosphors constituted by various combinations of L Element, M Element, and Z Element as L×MyN(2/3x+4/3y):Z phosphors. JP-A-2004-10786 (Patent Literature 7) describes a wide range of combinations regarding an L-M-N:Eu,Z system but there is not shown an effect of improving emission properties in the cases that a specific composition or crystal phase is used as a host.
The representative phosphors in Patent Literatures 2 to 7 mentioned above contain nitrides of a divalent element and a tetravalent element as host crystals and phosphors using various different crystal phases as host crystals have been reported. The phosphors emitting a light of red color are also known but the emitting luminance of red color is not sufficient by excitation with a blue visible light. Moreover, they are chemically unstable in some compositions and thus their durability is problematic.
[Non-Patent Literature 1]


    H. A. Hoppe, and other four persons, “Journal of Physics and Chemistry of Solids” 2000, vol. 61, pages 2001-2006

[Non-Patent Literature 2]

    “On new rare-earth doped M-Si—Al—O—N materials” written by J. W. H. van Krevel, TU Eindhoven 2000, ISBN, 90-386-2711-4

[Patent Literature 1]

    JP-A-2002-363554

[Patent Literature 2]

    U.S. Pat. No. 6,682,663

[Patent Literature 3]

    JP-A-2003-206481

[Patent Literature 4]

    JP-A-2002-322474

[Patent Literature 5]

    JP-A-2003-321675

[Patent Literature 6]

    JP-A-2003-277746

[Patent Literature 7]

    JP-A-2004-10786


As conventional art of lighting apparatus, a white light-emitting diode wherein a blue light-emitting diode element and a blue light-absorbing yellow light-emitting phosphor are combined is known and has been practically used in various lighting applications. Representative examples thereof include “a light-emitting diode” of Japanese Patent No. 2900928 (Patent Literature 8), “a light-emitting diode” of Japanese Patent No. 2927279 (Patent Literature 9), “a wavelength-converting molding material and a process for producing the same, and a light-emitting element” of Japanese Patent No. 3364229 (Patent Literature 10), and the like. Phosphors most frequently used in these light-emitting diode are yttrium.aluminum.garnet-based phosphors activated with cerium represented by the general formula: (Y,Gd)3(Al,Ga):Ce3+.
However, there is a problem that the white light-emitting diode comprising a blue light-emitting diode element and the yttrium.aluminum.garnet-based phosphor has a characteristic of emitting a bluish-white light because of an insufficient red component and hence deflection is found in color-rendering properties.
Based on such a background, there has been investigated a white light-emitting diode wherein a red component which is short in the yttrium.aluminum.garnet-based phosphor is supplemented with another red phosphor by mixing and dispersing two kinds of phosphors. As such light-emitting diodes, “a white light-emitting diode” of JP-A-10-163535 (Patent Literature 11), “a nitride phosphor and a process for producing the same” of JP-A-2003-321675 (Patent Literature 5), and the like can be exemplified. However, a problem to be improved regarding color-rendering properties still remains also in these inventions, and hence it is desired to develop a light-emitting diode where the problem is solved. The red phosphor described in JP-A-10-163535 (Patent Literature 11) contains cadmium and thus there is a problem of environmental pollution. Although red light emitting phosphors including Ca1.97Si5N8:Eu0.03 described in JP-A-2003-321675 (Patent Literature 5) as a representative example do not contain cadmium but further improvement of their emission intensities has been desired since luminance of the phosphor is low.
[Patent Literature 8]


    Japanese Patent No. 2900928

[Patent Literature 9]

    Japanese Patent No. 2927279

[Patent Literature 10]

    Japanese Patent No. 3364229

[Patent Literature 11]

    JP-A-10-163535


DISCLOSURE OF THE INVENTION
The invention intends to reply such demands and an object thereof is to provide an inorganic phosphor which emits an orange or red light having a longer wavelength than that of conventional sialon phosphors activated with a rare earth, has a high luminance, and is chemically stable. Furthermore, another object of the invention is to provide alighting equipment excellent in color-rendering properties, an image display unit excellent in durability, a pigment, and an ultraviolet absorbent using such a phosphor.
Under such circumstances, the present inventors have conducted precise studies on phosphors using as a host an inorganic multi-element nitride crystal phase containing trivalent E Element such as Al in addition to divalent A Element such as Ca and tetravalent D Element such as Si as main metal elements and have found that a phosphor using an inorganic crystal phase having a specific composition or a specific crystal structure as a host emits an orange or red light having a longer wavelength than that of conventional sialon phosphors activated with a rare earth and also exhibits a higher luminance than that of the red phosphors hitherto reported containing a nitride or oxynitride as a host crystal.
Namely, as a result of extensive studies on inorganic compounds mainly composed of nitrides or oxynitrides containing M Element which becomes a light-emitting ion (wherein M Element is one or two or more elements selected from Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb) and divalent A Element (wherein A Element is one or two or more elements selected from Mg, Ca, Sr, and Ba), tetravalent D Element (wherein D Element is one or two or more elements selected from Si, Ge, Sn, Ti, Zr, and Hf), trivalent E Element (wherein E Element is one or two or more elements selected from B, Al, Ga, In, Sc, Y, La, Gd and Lu), and X Element (wherein X Element is one or two or more elements selected from O, N, and F), they have found that those having a specific composition region range and a specific crystal phase form phosphors emitting an orange light having a wavelength of 570 nm or longer or a red light having a wavelength of 600 nm or longer.
Furthermore, they have found that, among the above compositions, a solid solution crystal phase containing an inorganic compound having the same crystal structure as that of the CaAlSiN3 crystal phase as a host crystal and incorporated with an optically active element M, particularly Eu as an emission center forms a phosphor emitting an orange or red light having an especially high luminance. Furthermore, they have found that a white light-emitting diode which has a high emission efficiency, is rich in a red component, and exhibits good color-rendering properties can be obtained by using the phosphor.
The host crystal of the phosphor of the invention achieves red-light emission exhibiting an unprecedented luminance by using the multi-element nitride wherein a trivalent element including Al as a representative is used as a main constitutive metal element, quite unlike the ternary nitrides containing divalent and tetravalent elements hitherto reported including LxMyN(2/3x+4/3y) as a representative. Moreover, the invention is a novel phosphor using a crystal phase having a composition and crystal structure quite different from the sialons such as M13Si18Al12O18N36, MSi5Al2ON9, and M3Si5AlON10 (wherein M represents Ca, Ba, Sr, or the like) hitherto reported in Patent Literature 3 and the like and Ca1.47Eu0.03Si9Al3N16 described in Chapter 11 of Non-Patent Literature 2 as a host. Furthermore, unlike the crystal phase containing Al in an amount of about: several hundreds of ppm described in Patent Literature 5, it is a phosphor using as a host a crystal phase wherein a trivalent element including Al as a representative is a main constitutive element of the host crystal.
In general, a phosphor wherein an inorganic host crystal is activated with Mn or a rare earth metal as an emission center element M changes an emitting color and luminance depending on an electron state around M Element. For example, in a phosphor containing divalent Eu as the emission center, light emission of blue color, green color, yellow color, or red color has been reported by changing the host crystal. Namely, even in the case that the composition is resemble, when the crystal structure of the host or the atom position in the crystal structure to which M is incorporated is changed, the emitting color and luminance become quite different and thus the resulting phosphor is regarded as a different one. In the invention, a multi-element nitride containing divalent-trivalent-tetravalent elements different from conventional ternary nitrides containing divalent and tetravalent elements is used as a host crystal and furthermore, a crystal phase having a crystal structure quite different from that of the sialon composition hitherto reported is used as a host. Thus, the phosphor having such a crystal phase as a host has not hitherto been reported. In addition, the phosphor containing the composition and crystal structure of the invention as a host exhibits a red light emission having luminance higher than that of those containing a conventional crystal structure as a host.
The above CaAlSiN3 crystal phase itself is a nitride whose formation in the process of baking an Si3N4—AlN—CaO based raw material is confirmed by ZHEN-KUN-HUANG et al. for the purpose of aiming at a heat-resistant material. A process of the formation and a mechanism of the formation are precisely reported in an academic literature (c.f. Non-Patent Literature 3), which has been published prior to the present application.
[Non-Patent Literature 3]


    ZHEN-KUN-HUANG and other two persons, “Journal of Materials Science Letters” 1985, vol. 4, pages 255-259


As mentioned above, the CaAlSiN3 crystal phase itself is confirmed in the progress of the study of sialons. Also, from the circumstances, the content: of the report described in the above literature only mentions heat-resistant properties and the literature does not describe any matter that an optically active element may be dissolved in the crystal phase and the dissolved crystal phase may be used as a phosphor. Moreover, over the period from that time to the present invention, there is no investigation to use it as a phosphor. Namely, the important findings that a substance obtained by dissolving an optically active element in CaAlSiN3 crystal phase is a novel substance and it is usable as a phosphor capable of being excited with an ultraviolet ray and a visible light and exhibiting an orange or red light emission having a high luminance have been first found by the present inventors. As a result of further extensive studies based on the findings, the inventors have succeeded in providing a phosphor showing an emission phenomenon with a high luminance in a specific wavelength region by the constitutions described in the following (1) to (24). Moreover, they have also succeeded in providing a lighting equipment and an image display unit having excellent characteristics by the constitutions described in the following (25) to (37) by using the phosphor. Furthermore, by applying the inorganic compound as the phosphor to the constitutions described in the following (38) to (39), they have also succeeded in providing a pigment and an ultraviolet absorbent. Namely, as a result of a series of experiments and studies based on the above findings, the invention has succeeded in providing a phosphor emitting a light with a high luminance in a long wavelength region as well as a lighting equipment, an image display unit, a pigment, and an ultraviolet absorbent utilizing the phosphor. The constitutions are as described in the following (1) to (39).
(1) A phosphor comprising an inorganic compound which is a composition containing at least M Element, A Element, D Element, E Element, and X Element (wherein M Element is one or two or more elements selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb, A Element is one or two or more elements selected from the group consisting of divalent metal elements other than M Element, D Element is one or two or more elements selected from the group consisting of tetravalent metal elements, E Element is one or two or more elements selected from the group consisting of trivalent metal elements, and X Element is one or two or more elements selected from the group consisting of O, N, and F).
(2) The phosphor according to the above item (1), wherein the inorganic compound has the same crystal structure as that of CaAlSiN3.
(3) The phosphor according to the above item (1) or (2), wherein the inorganic compound is represented by the composition formula MaAbDcEdXe (wherein a+b=1 and M Element is one or two or more elements selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb, A Element is one or two or more elements selected from the group consisting of divalent metal elements other than M Element, D Element is one or two or more elements selected from the group consisting of tetravalent metal elements, E Element is one or two or more elements selected from the group consisting of trivalent metal elements, and X Element is one or two or more elements selected from the group consisting of O, N, and F), wherein the parameters a, c, d, and e satisfy all the requirements:

0.00001≦a≦0.1  (i),

0.5≦c≦4  (ii),

0.5≦d≦8  (iii),

0.8×(2/3+4/3×c+d)≦e  (iv),

and

e≦1.2×(2/3+4/3×c+d)  (v).

(4) The phosphor according to the above item (3), wherein the parameters c and d satisfy the requirements of 0.5≦c≦1.8 and 0.5≦d≦1.8.
(5) The phosphor according to the above item (3) or (4), wherein the parameters c, d, and e are c=d=1 and e=3.
(6) The phosphor according to any one of the above items (1) to (5), wherein A Element is one or two or more elements selected from the group consisting of Mg, Ca, Sr, and Ba, D Element is one or two or more elements selected from the group consisting of Si, Ge, Sn, Ti, Zr, and Hf, and E Element is one or two or more elements selected from the group consisting of B, Al, Ga, In, Sc, Y, La, Gd, and Lu.
(7) The phosphor according to any one of the above items (1) to (6), which contains, at least, Eu in M Element, Ca in A Element, Si in D Element, Al in E Element, and N in X Element.
(8) The phosphor according to any one of the above items (1) to (7), wherein the inorganic compound is a CaAlSiN3 crystal phase or a solid solution of a CaAlSiN3 crystal phase.
(9) The phosphor according to any one of the above items (1) to (8), wherein M Element is Eu, A Element is Ca, D Element is Si, E Element is Al, and X Element is N or a mixture of N and O.
(10) The phosphor according to any one of the above items (1) to (9), which contains, at least, Sr in A Element.
(11) The phosphor according to the above item (10), wherein numbers of atoms of Ca and Sr contained in the inorganic compound satisfy 0.02 (number of atoms of Ca)/{(number of atoms of Ca)+(number of atoms of Sr)}<1.
(12) The phosphor according to any one of the above items (1) to (11), which contains, at least, N and O in X.
(13) The phosphor according to the above item (12), wherein numbers of atoms of O and N contained in the inorganic compound satisfy 0.5≦(number of atoms of N)/{(number of atoms of N)+(number of atoms of O)}≦1.
(14) The phosphor according to the above item (12) or (13), wherein the inorganic compound is represented by MaAbD1−xE1+xN3-xOx (wherein a+b=1 and 0<x≦0.5).
(15) The phosphor according to any one of the above items (1) to (14), wherein the inorganic compound is a powder having an average particle size of 0.1 μm to 20 μm and the powder is single crystal particles or an aggregate of single crystals.
(16) The phosphor according to any one of the above items (1) to (15), wherein total of impurity elements of Fe, Co, and Ni contained in the inorganic compound is 500 ppm or less.
(17) A phosphor which is constituted by a mixture of the phosphor comprising the inorganic compound according to anyone of the above items (1) to (16) and other crystal phase or an amorphous phase and wherein the content of the phosphor comprising the inorganic compound according to any one of the above items (1) to (16) is 20% by weight or more.
(18) The phosphor according to the above item (17), wherein the other crystal phase or amorphous phase is an inorganic substance having electroconductivity.
(19) The phosphor according to the above item (18), wherein the inorganic substance having electroconductivity is an oxide, oxynitride, or nitride containing one or two or more elements selected from the group consisting of Zn, Al, Ga, In, and Sn, or a mixture thereof.
(20) The phosphor according to the above item (17), wherein the other crystal phase or amorphous phase is an inorganic phosphor different from the phosphor according to any one of the above items (1) to (16).
(21) The phosphor according to any one of the above items (1) to (20), which emits a fluorescent light having a peak in the range of a wavelength of 570 nm to 700 nm by irradiation with an excitation source.
(22) The phosphor according to the above item (21), wherein the excitation source is an ultraviolet ray or a visible light having a wavelength of 100 nm to 600 nm.
(23) The phosphor according to the above item (21), wherein the inorganic compound is a CaAlSiN3 crystal phase and Eu is dissolved in the crystal phase, and which emits a fluorescent light having a wavelength of 600 nm to 700 nm when irradiated with a light of 100 nm to 600 nm.
(24) The phosphor according to the above item (21), wherein the excitation source is an electron beam or an X-ray.
(25) The phosphor according to any one of the above items (21) to (24), wherein a color emitted at the irradiation with an excitation source satisfies a requirement: 0.45×0.7
as a value of (x, y) on the CIE chromaticity coordinates.
(26) A lighting equipment constituted by a light-emitting source and a phosphor, wherein at least the phosphor according to any one of the above items (1) to (25) is used.
(27) The lighting equipment according to the above item (26), wherein the light-emitting source is an LED emitting a light having a wavelength of 330 nm to 500 nm.
(28) The lighting equipment according to the above item (26) or (27), wherein the light-emitting source is an LED emitting a light having a wavelength of 330 nm to 420 nm and which emits a white light with mixing red, green, and blue lights by using the phosphor according to anyone of the above items (1) to (25), a blue phosphor having an emission peak at a wavelength of 420 nm to 500 nm with an excitation light of 330 nm to 420 nm, and a green phosphor having an emission peak at a wavelength of 500 nm to 570 nm with an excitation light of 330 nm to 420 nm.
(29) The lighting equipment according to the above item (26) or (27), wherein the light-emitting source is an LED emitting a light having a wavelength of 420 nm to 500 nm and which emits a white light by using the phosphor according to any one of the above items (1) to (25) and a green phosphor having an emission peak at a wavelength of 500 nm to 570 nm with an excitation light of 420 nm to 500 nm.
(30) The lighting equipment according to the above item (26) or (27), wherein the emitting source is an LED emitting a light having a wavelength of 420 nm to 500 nm and which emits a white light by using a phosphor according to any one of the above items (1) to (25) and a yellow phosphor having an emission peak at a wavelength of 550 nm to 600 nm with an excitation light of 420 nm to 500 nm.
(31) The lighting equipment according to the above item (30), wherein the yellow phosphor is a Ca-αsialon in which Eu is dissolved.
(32) An image display unit constituted by an excitation source and a phosphor, wherein at least the phosphor according to any one of the above items (1) to (25) is used.
(33) The image display unit according to the above item (32), wherein the excitation source is an LED emitting a light having a wavelength of 330 nm to 500 nm.
(34) The image display unit according to the above item (32) or (33), wherein the excitation source is an LED emitting a light having a wavelength of 330 nm to 420 nm and which emits a white light with mixing red, green, and blue lights by using the phosphor according to any one of the above items (1) to (25), a blue phosphor having an emission peak at a wavelength of 420 nm to 500 nm with an excitation light of 330 nm to 420 nm, and a green phosphor having an emission peak at a wavelength of 500 nm to 570 nm with an excitation light of 330 nm to 420 nm.
(35) The image display unit according to the above item (32) or (33), wherein the emitting source is an LED emitting a light having a wavelength of 420 nm to 500 nm and which emits a white light by using the phosphor according to any one of the above items (1) to (25) and a green phosphor having an emission peak at a wavelength of 500 nm to 570 nm with an excitation light of 420 nm to 500 nm.
(36) The image display unit according to the above item (32) or (33), wherein the emitting source is an LED emitting a light having a wavelength of 420 nm to 500 nm and which emits a white light by using the phosphor according to any one of the above items (1) to (25) and a yellow phosphor having an emission peak at a wavelength of 550 nm to 600 nm with an excitation light of 420 nm to 500 nm.
(37) The image display unit according to the above item (36), wherein the yellow phosphor is a Ca-αsialon in which Eu is dissolved.
(38) The image display unit according to the above items (32) to (37), wherein the image display unit is any of a vacuum fluorescent display (VFD), a field emission display (FED), a plasma display panel (PDP), and a cathode-ray tube (CRT).
(39) A pigment comprising the inorganic compound according to any one of the above items (1) to (25).
(40) An ultraviolet absorbent comprising the inorganic compound according to any one of the above items (1) to (25).
The phosphor of the invention contains a multi-element nitride containing a divalent element, a trivalent element, and a tetravalent element, particularly a crystal phase represented by CaAlSiN3, another crystal phase having the same crystal structure as it, or a solid solution of these crystal phases as a main component and thereby exhibits light emission at a longer wavelength than that in the cases of conventional sialon and oxynitride phosphors, so that the phosphor of the invention is excellent as an orange or red phosphor. Even when exposed to an excitation source, the phosphor does not exhibit decrease of luminance and thus provides a useful phosphor which is suitably employed in VFD, FED, PDP, CRT, white LED, and the like. Moreover, among the phosphors, since the host of a specific inorganic compound has a red color and the compound absorbs an ultraviolet ray, it is suitable as a red pigment and an ultraviolet absorbent.



BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-1 is an X-ray diffraction chart of CaAlSiN3.
FIGS. 1-2 is an X-ray diffraction chart of CaAlSiN3 activated with Eu (Example 1).
FIG. 2 is a drawing illustrating a crystal structure model of CaAlSiN3.
FIG. 3 is a drawing illustrating a crystal structure model of Si2N2O having a similar structure to the CaAlSiN3 crystal phase.
FIG. 4 is a drawing illustrating emission spectra of phosphors (Examples 1 to 7).
FIG. 5 is a drawing illustrating excitation spectra of phosphors (Examples 1 to 7).
FIG. 6 is a drawing illustrating emission spectra of phosphors (Examples 8 to 11).
FIG. 7 is a drawing illustrating excitation spectra of phosphors (Examples 8 to 11).
FIG. 8 is a drawing illustrating emission spectra of phosphors (Examples 12 to 15).
FIG. 9 is a drawing illustrating excitation spectra of phosphors (Examples 12 to 15).
FIG. 10 is a drawing illustrating emission spectra of phosphors (Examples 16 to 25).
FIG. 11 is a drawing illustrating excitation spectra of phosphors (Examples 16 to 25).
FIG. 12 is a drawing illustrating emission spectra of phosphors (Examples 26 to 30).
FIG. 13 is a drawing illustrating excitation spectra of phosphors (Examples 26 to 30).
FIG. 14 is a schematic drawing of the lighting equipment (LED lighting equipment) according to the invention.
FIG. 15 is a schematic drawing of the image display unit (plasma display panel) according to the invention.



In this connection, with regard to the symbols in the figures, 1 represents a mixture of a red phosphor of the invention and a yellow phosphor or a mixture of a red phosphor of the invention, a blue phosphor, and a green phosphor, 2 represents an LED chip, 3 and 4 represent electroconductive terminals, 5 represents a wire bond, 6 represents a resin layer, 7 represents a container, 8 represents a red phosphor of the invention, 9 represents a green phosphor, 10 represents a blue phosphor, 11, 12, and 13 represent ultraviolet ray-emitting cells, 14, 15, 16, and 17 represent electrodes, 18 and 19 represent dielectric layers, 20 represents a protective layer, and 21 and 22 represent glass substrates.
BEST MODE FOR CARRYING OUT THE INVENTION
The following will describe the present invention in detail with reference to Examples of the invention.
The phosphor of the invention comprises an inorganic compound which is (1) a composition containing at least M Element, A Element, D Element, E Element, and X Element (wherein M Element is one or two or more elements selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb, A Element is one or two or more elements selected from the group consisting of divalent metal elements other than M Element, D Element is one or two or more elements selected from the group consisting of tetravalent metal elements, E Element is one or two or more elements selected from the group consisting of trivalent metal elements, and X Element is one or two or more elements selected from the group consisting of O, N, and F) and is (2) (a) a crystal phase represented by the chemical formula CaAlSiN3, (b) another crystal phase having the same crystal structure as that of the crystal phase, or (c) a solid solution of these crystal phases (hereinafter, these crystal phases are collectively referred to as “a CaAlSiN3 family crystal phase”). Such a phosphor of the invention shows a particularly high luminance.
M Element is one or two or more elements selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb. M Element is preferably one or two or more elements selected from the group consisting of Mn, Ce, Sm, Eu, Tb, Dy, Er, and Yb. M Element more preferably contains Eu and is still more preferably Eu.
A Element is one or two or more elements selected from the group consisting of divalent metal elements other than M Element. Particularly, A Element is preferably one or two or more elements selected from the group consisting of Mg, Ca, Sr, and Ba and is more preferably Ca.
D Element is one or two or more elements selected from the group consisting of tetravalent metal elements. Particularly, D Element is preferably one or two or more elements selected from the group consisting of Si, Ge, Sn, Ti, Zr, and Hf and is more preferably Si.
E Element is one or two or more elements selected from the group consisting of trivalent metal elements. Particularly, E Element is one or two or more elements selected from the group consisting of B, Al, Ga, In, Sc, Y, La, Gd, and Lu and is more preferably Al.
X Element is one or two or more elements selected from the group consisting of O, N, and F. Particularly, X Element is preferably composed of N or N and O.
The composition is represented by the composition formula MaAbDcEdXe. A composition formula is a ratio of numbers of the atoms constituting the substance and one obtained by multiplying a, b, c, d, and e by an arbitrary number has also the same composition. Therefore, in the invention, the following requirements are determined to the one obtained by recalculation for a, b, c, d, and e so as to be a+b=1.
In the invention, the values of a, c, d, and e are selected from the values satisfying all the following requirements:

0.00001≦a≦0.1  (i),

0.5≦c≦4  (ii),

0.5≦d≦8  (iii),

0.8×(2/3+4/3×c+d)≦e  (iv),

e≦1.2×(2/3+4/3×c+d)  (v).

a represents an adding amount of M Element which becomes an emission center and the ratio a of numbers of atoms M and (M+A) (wherein a=M/(M+A)) in a phosphor is suitably from 0.00001 to 0.1. When a Value is less than 0.00001, the number of M becoming an emmision center is small and hence emission luminance decreases. When a Value is larger than 0.1, concentration quenching occurs owing to interference between M ions, so that luminance decreases.
In particular, in the case that M is Eu, a Value is preferably from 0.002 to 0.03 owing to high emission luminance.
c Value is the content of D Element such as Si and is an amount represented by 0.5≦c≦4. The value is preferably 0.5≦c≦1.8, more preferably c=1. When c Value is less than 0.5 and when the value is larger than 4, emission luminance decreases. In the range of 0.5≦c≦1.8, emission luminance is high and particularly, emission luminance is especially high at c=1. The reason therefor is that the ratio of formation of the CaAlSiN3 family crystal phase to be described below increases.
d Value is the content of E Element such as Al and is an amount represented by 0.5≦d≦8 The value is preferably 0.5≦d≦1.8, more preferably d=1. When d Value is less than 0.5 and when the value is larger than 8, emission luminance decreases. In the range of 0.5≦d≦1.8, emission luminance is high and particularly, emission luminance is especially high at d=1. The reason therefor is that the ratio of formation of the CaAlSiN3 family crystal phase to be described below increases.
e Value is the content of X Element such as N and is an amount represented by from 0.8×(2/3+4/3×c+d) to 1.2×(2/3+4/3×c+d). More preferably, e=3. The reason therefor is that the ratio of formation of the CaAlSiN3 family crystal phase to be described below increases. When e Value is out of the range, emission luminance decreases.
Among the above compositions, compositions exhibiting a high emission luminance are those which contain, at least, Eu in M Element, Ca in A Element, Si in D Element, Al in E Element, and N in X Element. In particular, the composition are those wherein M Element is Eu, A Element is Ca, D Element is Si, E Element is Al, and X Element is N or a mixture of N and O.
The above CaAlSiN3 crystal phase is an orthorhombic system and is a substance characterized by a crystal phase having lattice constants of a=9.8007(4) Å, b=5.6497(2) Å, and c=5.0627(2) Å and having indices of crystal plane described in the chart of FIGS. 1-1 and Table 4 in X-ray diffraction.
According to the crystal structure analysis of the CaAlSiN3 crystal phase conducted by the inventors, the present crystal phase belongs to Cmc21 (36th space group of International Tables for Crystallography) and occupies an atomic coordinate position shown in Table 5. In this connection, the space group is determined by convergent beam electron diffraction and the atomic coordinate is determined by Rietveld analysis of X-ray diffraction results.
The crystal phase has a structure shown in FIG. 2 and has a similar skeleton to the Si2N2O crystal phase (mineral name: sinoite) shown in FIG. 3. Namely, the crystal phase is a crystal phase wherein the position of Si in the Si2N2O crystal phase is occupied by Si and Al and the positions of N and O are occupied by N, and Ca is incorporated as an interstitial element into a space of the skeleton formed by Si—N—O, and has a structure where the atomic coordinates are changed to the positions shown in Table 5 with the replacement of the elements. Si and Al occupy the Si position in the Si2N2O crystal phase in an irregularly distributed (disordered) state. Thus, this structure is named as a sinoite-type sialon structure.
The inorganic compound having the same crystal structure as CaAlSiN3 shown in the invention means the inorganic compound which is a CaAlSiN3 family crystal phase mentioned above. The inorganic compound having the same crystal structure as CaAlSiN3 includes those having lattice constants changed by the replacement of the constitutive element(s) with other element(s) in addition to the substances showing the same diffraction as the results of X-ray diffraction of CaAlSiN3. For example, a CaAlSiN3 crystal phase, a solid solution of the CaAlSiN3 crystal phase, and the like may be mentioned. Herein, one wherein the constitutive element (s) are replaced with other element (s) means a crystal phase wherein, in the case of the CaAlSiN3 crystal phase, for example, Ca in the crystal phase is replaced with M Element (wherein M Element is one or two or more elements selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb) and/or M Element and one or two or more elements selected from the group consisting of divalent metal elements other than Ca, preferably the group consisting of Mg, Sr, and Ba, Si is replaced with one or two or more elements selected from the group consisting of tetravalent metal elements other than Si, preferably the group consisting of Ge, Sn, Ti, Zr, and Hf, Al is replaced with one or two or more elements selected from the group consisting of trivalent metal elements other than Al, preferably the group consisting of B, Ga, In, Sc, Y, La, Gd, and Lu, and N is replaced with one or two or more elements selected from the group consisting of O and F. In this connection, the CaAlSiN3 family crystal phase of the invention can be identified by X-ray diffraction or neutron-ray diffraction.
The CaAlSiN3 family crystal phase is changed in lattice constants by the replacement of Ca, Si, Al, or N as the constitutive components with other element(s) or the dissolution of a metal element such as Eu but the atomic position determined by the crystal structure, the site occupied by the atom, and its coordinate is changed to not so large extent that the chemical bond between skeletal atoms is cleaved. In the invention, in the case that the lengths of chemical bonds of Al—N and Si—N (distance between adjacent atoms) calculated from the lattice constants and atomic coordinates determined by Rietveld analysis of the results of X-ray diffraction and neutron-ray diffraction with the space group of Cmc21 are within ±15% as compared with the length of the chemical bond calculated from the lattice constants and atomic coordinates of CaAlSiN3 shown in Table 5, it is defined that the crystal phase has the same crystal structure. In this manner, a crystal phase is judged whether it is a CaAlSiN3 family crystal phase or not. This judging standard is based on the fact that, when the length of the chemical bond changes beyond ±15%, the chemical bond is cleaved and another crystal phase is formed.
Furthermore, when the dissolved amount is small, the following method may be a convenient judging method of a CaAlSiN3 family crystal phase. When the lattice constants calculated from the results of X-ray diffraction measured on a new substance and the peak position (20) of diffraction calculated using the indices of crystal plane in Table 4 are coincident with regard to main peaks, the crystal structures can be identified to be the same. As the main peaks, it is appropriate to conduct the judgment on about ten peaks exhibiting strong diffraction intensity. In that sense, Table 4 is a standard for identifying the CaAlSiN3 family crystal phase and thus is of importance. Moreover, with regard to the crystal structure of the CaAlSiN3 crystal phase, an approximate structure can be defined also using another crystal system such as a monoclinic system or a hexagonal system. In that case, the expression may be one using different space group, lattice constants, and indices of crystal plane but the results of X-ray diffraction are not changed and the identification method and identification results using the same are identical thereto. Therefore, in the invention, X-ray diffraction is analyzed as an orthorhombic system. The identification method of substances based on Table 4 will be specifically described in Example 1 to be described below and only a schematic explanation is conducted here.
A phosphor is obtained by activating a CaAlSiN3 family crystal phase with M Element (wherein M Element is one or two or more elements selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb). The phosphor having a particularly high luminance among the CaAlSiN3 family crystal phases is a phosphor containing as a host a CaAlSiN3 crystal phase using a combination that A is Ca, D is Si, E is Al, and X is N.
A phosphor using CaxSr1-xAlSiN3 (wherein 0.02≦x≦1) crystal phase which is a crystal phase obtained by replacing part of Ca with Sr or its solid solution as host crystals, i.e., a phosphor wherein numbers of atoms of Ca and Sr contained in the inorganic compound satisfy 0.02≦(number of atoms of Ca)/{(number of atoms of Ca)+(number of atoms of Sr)}<1, becomes a phosphor exhibiting a shorter wavelength than that of the phosphor using as a host a CaAlSiN3 crystal phase having a composition of the range.
The phosphor using as a host an inorganic compound containing nitrogen and oxygen is excellent in durability in a high-temperature air. In this case, durability at a high temperature is particularly excellent at the composition where numbers of atoms of O and N contained in the inorganic compound satisfy 0.5≦(number of atoms of N)/{(number of atoms of N)+(number of atoms of O)}1.
In the case that the inorganic compound containing nitrogen and oxygen is used as a host, since the ratio of formation of the CaAlSiN3 family crystal phase increases at the composition represented by MaA1,D1−xE1+xN3−xOx (wherein a+b=1 and 0<x≦0.5), emission luminance is high. This is because trivalent N is replaced with divalent O by the number of the atom the same as the number of the tetravalent D Element replaced with trivalent E Element in the composition and hence charge neutrality is maintained, so that a stable CaAlSiN3 family crystal phase is formed.
In the case that the phosphor comprising the inorganic compound having the same crystal structure as CaAlSiN3 of the invention is used as a powder, the average particle size of the inorganic compound is preferably from 0.1 μm to 20 μm in view of dispersibility into the resin and fluidity of the powder. Moreover, the powder is single crystal particles or an aggregate of single crystals but emission luminance is further improved by using single crystal particles having an average particle size of 0.1 μM to 20 μm.
In order to obtain a phosphor exhibiting a high emission luminance, the amount of impurities contained in the inorganic compound is preferably as small as possible. In particular, since the contamination of a large amount of Fe, Co, and Ni impurity elements inhibits light emission, it is suitable that raw powders are selected and the synthetic steps are controlled so that the total of these elements becomes not more than 500 ppm.
In the invention, from the viewpoint of fluorescence emission, it is desirable that the nitride contain the CaAlSiN3 family crystal phase as a constitutive component of the nitride in high purity and as much as possible, and is possibly composed of a single phase, but it may be composed of a mixture thereof with the other crystal phases or an amorphous phase within the range where the characteristics do not decrease. In this case, it is desirable that the content of the CaAlSiN3 family crystal phase is 50% by weight or more in order to obtain a high luminance. Further preferably, when the content is 20% by weight or more, luminance is remarkably improved. In the invention, the range as a main component is a content of the CaAlSiN3 family crystal phase of at least 20% by weight or more. The ratio of content of the CaAlSiN3 family crystal phase can be determined from the ratio of the intensity of the strongest peaks in respective phases of the CaAlSiN3 family crystal phase and the other crystal phases through the measurement of X-ray diffraction.
In the case that the phosphor of the invention is used for applications excited with an electron beam, electroconductivity can be imparted to the phosphor by mixing it with an inorganic substance having electroconductivity. As the inorganic substance having electroconductivity, there may be mentioned oxides, oxynitrides, or nitrides containing one or two or more elements selected from the group consisting of Zn, Al, Ga, In, and Sn, or mixtures thereof.
The phosphor of the invention can emit a red light by the combination of a specific host crystal and an activating element but, in the case that mixing with the other colors such as yellow color, green color, and blue color is necessary, it is possible to mix inorganic phosphors emitting lights of these colors according to necessity.
The phosphors of the invention exhibit different excitation spectra and fluorescent spectra depending on the composition and hence can be set at those having various emission spectra by suitably selecting and combining them. The embodiment maybe appropriately set at a required spectrum based on the application. Particularly, one wherein Eu is added to the CaAlSiN3 crystal phase in a composition of 0.0001≦(number of atoms of Eu)/{(number of atoms of Eu)+(number of atoms of Ca)}≦0.1 exhibits emission of a light having a peak in the range of a wavelength of 600 nm to 700 nm when excited with a light having a wavelength in the range of 100 nm to 600 nm, preferably 200 nm to 600 nm, and exhibits excellent emission characteristics as red fluorescence.
The phosphors of the invention obtained as above are characterized in that they have a wide excitation range of from an electron beam or an X-ray and an ultraviolet ray to a visible light, i.e., ultraviolet rays or visible lights having wavelengths from 100 nm to 600 nm, emit an orange to red light of 570 nm or longer, and particularly exhibit red color of 600 nm to 700 nm at a specific composition, and they exhibit a red light ranging 0.45≦x≦0.7 in terms of the value of (x, y) on CIE chromaticity coordinates, as compared with conventional oxide phosphors and existing sialon phosphors. Owing to the above emission characteristics, they are suitable for a lighting equipment, an image display unit, a pigment, and an ultraviolet absorbent. In addition, since they are not degraded even when exposed to a high temperature, they are excellent in heat resistance and also excellent in long-term stability under an oxidizing atmosphere and under a moist environment.
The phosphors of the invention do not limit the production process but a phosphor exhibiting a high luminance can be produced by the following process.
A high-luminance phosphor is obtained by baking a raw material mixture, which is a mixture of metal compounds and may constitute a composition represented by M, A, D, E, and X by baking the mixture, at a temperature range of 1200° C. to 2200° C. in an inert atmosphere containing nitrogen.
In the case of synthesizing CaAlSiN3 activated with Eu, it is suitable to use a powder mixture of europium nitride or europium oxide, calcium nitride, silicon nitride, and aluminum nitride as a starting material.
Moreover, in the case of synthesizing a composition containing strontium, incorporation of strontium nitride in addition to the above affords a stable (Ca, Sr)AlSiN3 crystal phase wherein part of the calcium atoms in the crystal phase is replaced with strontium, whereby a high-luminance phosphor is obtained.
In the case of synthesizing a phosphor using as a host CaAlSi(O, N)3 and activated with Eu, wherein part of the nitrogen atom in the crystal phase is replaced with oxygen, a starting material of a mixture of europium nitride, calcium nitride, silicon nitride, and aluminum nitride is preferable in the composition of a small oxygen content since the material has a high reactivity and the synthesis in high yields is possible. In this case, as oxygen, oxygen impurity contained in the raw material powders of europium nitride, calcium nitride, silicon nitride, and aluminum nitride is used.
In the case of synthesizing a phosphor of a large oxygen content using CaAlSi(O, N)3 activated with Eu as a host, when a mixture of either of europium nitride or europium oxide or a mixture thereof, anyone of calcium nitride, calcium oxide, or calcium carbonate or a mixture thereof, silicon nitride, and aluminum nitride or a mixture of aluminum nitride and aluminum oxide is used as a starting material, the material has a high reactivity and the synthesis in high yields is possible.
It is appropriate that the above mixed powder of the metal compounds is baked in a state that a volume filling rate is maintained to 40% or less. In this connection, the volume filling rate can be determined according to (bulk density of mixed powder)/(theoretical density of mixed powder)×100[%]. As a vessel, a boron nitride sintered article is suitable because of low reactivity with the metal compounds.
The reason why the powder is baked in a state that a volume filling rate is maintained to 40% or less is that baking in the state that a free space is present around the starting powder enables synthesis of a crystal phase having little surface defect since the CaAlSiN3 family crystal phase as a reaction product grows in a free space and hence the contact of the crystal phases themselves decreases.
Next, a phosphor is synthesized by baking the resulting mixture of the metal compounds in a temperature range of 1200° C. to 2200° C. in an inert atmosphere containing nitrogen. Since the baking is conducted at a high temperature and the baking atmosphere is an inert atmosphere containing nitrogen, the furnace for use in the baking is a metal-resistor resistive heating type one or a graphite resistive heating type one and an electric furnace using carbon as a material for a high-temperature part of the furnace is suitable. As the method of the baking, a sintering method of applying no mechanical pressure externally, such as an atmospheric sintering method or a gas pressure sintering method is preferred since baking is conducted while the volume filling rate is maintained at 40% or less.
In the case that the powder aggregate obtained by the baking is strongly adhered, it is pulverized by means of a pulverizing machine usually used industrially, such as a ball mill or a jet mill and the like. The pulverization is conducted until the average particle size reaches 20 μm or less. Particularly preferred is an average particle size of 0.1 μm to 5 μm. When the average particle size exceeds 20 μm, fluidity of the powder and dispersibility thereof into resins become worse and emission intensity becomes uneven from part to part at the time when an emission apparatus is formed in combination with a light-emitting element. When the size becomes 0.1 μm or less, the amount of defects on the surface of a phosphor powder becomes large and hence emission intensity decreases in some phosphor compositions.
Of the phosphors of the invention, the phosphors using the inorganic compound containing nitrogen and oxygen as a host can be also produced by the following process.
It is a process wherein oxygen is allowed to exist in the raw material to be baked so that the ratio (percentage) of mol number of oxygen to total mol number of nitrogen and oxygen in the raw material to be baked (hereinafter referred to as an “oxygen existing ratio in a raw material”) becomes from 1% to 20% in a state of a bulk density of 0.05 g/cm3 to 1 g/cm3 at a baking temperature of 1200° C. to 1750° C. at the time when a starting mixed powder containing an elementary substance and/or compound of M Element, a nitride of A Element, a nitride of D Element, and a nitride of E Element is baked.
The oxygen existing ratio in a raw material means a ratio (percentage) of mol number of oxygen to total mol number of nitrogen and oxygen in the raw material to be baked at baking and the nitrogen in the raw material to be baked is nitrogen derived from the raw powder, while the oxygen includes oxygen to be incorporated from the baking atmosphere into the material to be baked at baking in addition to the oxygen contained in the raw powder beforehand. The oxygen existing ratio in a raw material can be determined by the measurement using an oxygen nitrogen analyzer. The oxygen existing ratio in a raw material is preferably from 2% to 15%.
The method of allowing oxygen to exist in such an oxygen existing ratio in a raw material at baking includes:
(1) a method of using raw nitrides containing a desired concentration of oxygen as raw materials to be baked,
(2) a method of allowing raw nitrides to contain a desired concentration of oxygen by heating the raw nitrides beforehand under an oxygen-containing atmosphere,
(3) a method of mixing a raw nitride powder with an oxygen-containing compound powder to form a raw material to be baked,
(4) a method of introducing oxygen into the raw material to be baked by contaminating oxygen in the baking atmosphere at baking of raw nitrides and oxidizing the raw nitrides at baking, and the like. In order to produce a high-luminance phosphor industrially stably, preferred is (1) the method of using raw nitrides containing a desired concentration of oxygen as raw materials to be baked or (3) the method of mixing a raw nitride powder with an oxygen-containing compound powder to form a raw material to be baked. In particular, more preferred is a method of using raw nitrides containing a desired concentration of oxygen as raw materials to be baked and also mixing the raw nitride powder with an oxygen-containing compound powder to form a raw material to be used, which is a combination of the above methods (1) and (3).
In this case, the oxygen-containing compound powder is selected from substances which form metal oxides at baking. As these substances, use can be made of oxides, inorganic acid salts such as nitrates, sulfates, and carbonates of respective metals, i.e., metals constituting the raw nitrides, organic acid salts such as oxalates and acetates thereof, oxygen-containing organometallic compounds, and the like, of respective metals, i.e., metals constituting the raw nitrides. However, from the viewpoints that oxygen concentration is easily controlled and association of impurity gases into the baking atmosphere can be suppressed at a low level, it is preferred to use metal oxides.
The oxygen existing ratio in raw material can be easily determined by conducting chemical analysis of all the raw materials. In particular, the ratio of nitrogen to oxygen can be determined by analyzing concentrations of nitrogen and oxygen.
The elementary substance and/or compound of M Element to be used as a raw material may be any substance as far as M Element is incorporated into a host crystal of the phosphor at a high temperature, including metals (elementary substances), oxides, nitrides, sulfides, halides, hydrides of M Element and also inorganic acid salts such as nitrates, sulfates, and carbonates, organic acid salts such as oxalates and acetates, organometallic compounds, and the like, and there is no limitation in its kind. However, from the viewpoint of good reactivity with other nitride materials, metals, oxides, nitrides, and halides of M Element are preferred and oxides are particularly preferred since the raw materials are available at a low cost and the temperature for phosphor synthesis can be lowered.
In the case of using at least Eu as M Element, use can be made of one or two or more of Eu metal containing Eu as a constitutive element, europium oxide such as EuO and Eu2O3, and various compounds such as EuN, EuH3, Eu2S3, EuF2, EuF3, EuCl2, EuCl3, Eu (NO3)3, EU2 (SO4)3, EU2 (CO3)3, EU (C2O4)3, EU (O-i-C3H7)3, but Eu halides such as EuF2, EuF3, EuCl2, and EuCl3 are preferred since they have an effect of accelerating crystal growth. Moreover, Eu2O3 and Eu metal are also preferred since a phosphor having excellent characteristics can be synthesized from them. Of these, Eu2O3 is particularly preferred, which is cheap in a raw material cost, has little deliquescency, and enables synthesis of a high-luminance phosphor at a relatively low temperature.
As raw materials for elements other than M Element, i.e., raw materials for A, D, and E Elements, nitrides thereof are usually used. Examples of nitrides of A Element include one or two or more of Mg3N2, Ca3N2, Sr3N2, Ba3N2, Zn3N2, and the like, examples of nitrides of D Element include one or two or more of Si3N4, Ge3N4, Sn3N4, Ti3N4, Zr3N4, Hf3N4, and the like, and examples of nitrides of E Element include one or two or more of AlN, GaN, InN, ScN, and the like. The use of powders thereof is preferred since a phosphor having excellent emission characteristics can be produced.
In particular, the use, as raw materials of A Element, of a highly active and highly reactive nitride material having mol number of oxygen of 1% to 20% relative to the total mol number of nitrogen and oxygen remarkably accelerates the solid phase reaction between the raw mixed powder of nitrides and, as a result, it becomes possible to lower the baking temperature and atmosphere gas pressure at baking without subjecting the raw mixed powder to compression molding. For the same reason, it is preferred to use, as a raw material of A Element, a nitride material particularly having mol number of oxygen of 2% to 15% relative to the total mol number of nitrogen and oxygen.
When the bulk density of the raw mixed powder is too small, the solid phase reaction is difficult to proceed owing to small contact area between the powdery raw materials and hence an impurity phase which cannot lead to synthesis of a preferred phosphor may remain in a large amount. On the other hand, when the bulk density is too large, the resulting phosphor may become a hard sintered one, which not only requires a long-term pulverization step after baking but also tends to lower luminance of the phosphor. Therefore, the bulk density is preferably from 0.15 g/cm3 to 0.8 g/cm3.
When the baking temperature of the raw mixed powder is too low, the solid phase reaction is difficult to proceed and the aimed phosphor cannot be synthesized. On the other hand, when it is too high, not only unproductive baking energy is consumed but also evaporation of nitrogen from the starting material and the produced substance increases and hence there is a tendency that the aimed phosphor cannot be produced unless the pressure of nitrogen which constitutes part of atmosphere gas is increased to a very high pressure. Therefore, the baking temperature is preferably from 1300° C. to 1700° C. The baking atmosphere of the raw mixed powder is in principle an inert atmosphere or a reductive atmosphere but the use of an atmosphere containing a minute amount of oxygen wherein the oxygen concentration is in the range of 0.1 to 10 ppm is preferred since it becomes possible to synthesize a phosphor at a relatively low temperature.
Moreover, the pressure of atmosphere gas at baking is usually 20 atm (2 MPa) or lower. A high-temperature baking equipment comprising a strong heat-resistant vessel is required for a pressure exceeding 20 atm and hence the cost necessary for baking becomes high, so that the pressure of the atmosphere gas is preferably 10 atm (1 MPa) or lower. In order to prevent contamination of oxygen in the air, the pressure is preferably slight higher than 1 atm (0.1 MPa). In the case that air-tightness of the baking furnace is wrong, when the pressure is 1 atm (0.1 MPa) or lower, a lot of oxygen contaminates the atmosphere gas and hence it is difficult to obtain a phosphor having excellent characteristics.
Furthermore, the holding time at the maximum temperature at baking is usually from 1 minute to 100 hours. When the holding time is too short, the solid phase reaction between raw mixed powders does not sufficiently proceed and an aimed phosphor cannot be obtained. When the holding time is too long, not only unproductive baking energy is consumed but also nitrogen is eliminated from the surface of the phosphor and the fluorescence characteristics deteriorate. For the same reasons, the holding time is preferably from 10 minutes to 24 hours.
As explained in the above, the CaAlSiN3 family crystal phase phosphor of the invention exhibits a higher luminance than that of conventional sialon phosphors and, since decrease in luminance of the phosphor is small when it is exposed to an excitation source, it is a phosphor suitable for VFD, FED, PDP, CRT, white LED, and the like.
The lighting equipment of the invention is constituted by the use of at least a light-emitting source and the phosphor of the invention. As the lighting equipment, there may be mentioned an LED lighting equipment, a fluorescent lamp, and the like. The LED lighting equipment can be produced by known methods as described in JP-A-5-152609, JP-A-7-99345, Japanese Patent No. 2927279, and so forth with the phosphor of the invention. In this case, the light-emitting source is desirably one emitting a light having a wavelength of 330 to 500 nm, and particularly preferred is an ultraviolet (or violet) LED light-emitting element of 330 to 420 nm or a blue LED light-emitting element of 420 to 500 nm.
As these light-emitting elements, there exist an element comprising a nitride semiconductor such as GaN or InGaN and the like and, by adjusting the composition, it may be employed as a light-emitting source which emits a light having a predetermined wavelength.
In the lighting equipment, in addition to the method of using the phosphor of the invention solely, by the combined use thereof with a phosphor having other emission characteristics, a lighting equipment emitting a desired color can be constituted. As one example, there is a combination of an ultraviolet LED light-emitting element of 330 to 420 nm with a blue phosphor excited at the wavelength and having an emission peak at a wavelength of 420 nm to 500 nm, a green phosphor excited at the wavelength of 330 to 420 nm and having an emission peak at a wavelength of 500 nm to 570 nm, and the phosphor of the invention. There may be mentioned BaMgAl10O17:Eu as the blue phosphor and BaMgAl10O17:Eu,Mn as the green phosphor. In this constitution, when the phosphors are irradiated with an ultraviolet ray emitted by the LED, red, green, and blue lights are emitted and a white lighting equipment is formed by mixing the lights.
As an alternative method, there is a combination of a blue LED light-emitting element of 420 to 500 nm with a yellow phosphor excited at the wavelength and having an emission peak at a wavelength of 550 nm to 600 nm and the phosphor of the invention. As such a yellow phosphor, there may be mentioned (Y, Gd)2 (Al, Ga)5O12: Ce described in Japanese Patent No. 2927279 and α-sialon:Eu described in JP-A-2002-363554. Of these, a Ca-α-sialon in which Eu is dissolved is preferred owing to high emission luminance. In this constitution, when the phosphors are irradiated with a blue light emitted by the LED, two lights having red and yellow colors are emitted and the lights are mixed with the blue light of LED itself to form a lighting equipment exhibiting a white color or a reddish lamp color.
As another method, there is a combination of a blue LED light-emitting element of 420 to 500 nm with a green phosphor excited at the wavelength and having an emission peak at a wavelength of 500 nm to 570 nm and the phosphor of the invention. As such a green phosphor, there may be mentioned Y2Al5O12:Ce. In this constitution, when the phosphors are irradiated with a blue light emitted by the LED, two lights having red and green colors are emitted and the lights are mixed with the blue light of LED itself to form a white lighting equipment.
The image display unit of the invention is constituted by at least an excitation source and the phosphor of the invention and includes a vacuum fluorescent display (VFD), a field emission display (FED), a plasma display panel (PDP), a cathode ray tube (CRT), and the like. The phosphor of the invention is confirmed to emit a light by excitation with a vacuum ultraviolet ray of 100 to 190 nm, an ultraviolet ray of 190 to 380 nm, an electron beam, or the like. Thus, by the combination of any of these excitation sources and the phosphor of the invention, the image display unit as above can be constituted.
Since the specific inorganic compound of the invention has a red object color, it can be used as a red pigment or a red fluorescent pigment. When the inorganic compound of the invention is irradiated with illumination of sunlight, fluorescent lamp, or the like, a red object color is observed and the compound is suitable as an inorganic pigment owing to good coloring and no deterioration over a long period of time. Therefore, there is an advantage that the coloring does not decrease over a long period of time when it is used in coatings, inks, colors, glazes, colorants added to plastic products or the like. The nitride of the invention absorbs ultraviolet rays and hence is suitable as an ultraviolet absorbent. Therefore, when the nitride is used as a coating or applied on the surface of plastic products or kneaded into the products, the effect of shielding ultraviolet rays is high and thus the effect of protecting the products from ultraviolet degradation is high.
EXAMPLES
The following will describe the invention further in detail with reference to the following Examples but they are disclosed only for the purpose of easy understanding of the invention and the invention is not limited to these Examples.
Example 1
As raw powders were used a silicon nitride powder having an average particle size of 0.5 μm, an oxygen content of 0.93% by weight, and an α-type content of 92%, an aluminum nitride powder having a specific surface area of 3.3 m2/g and an oxygen content of 0.79%, a calcium nitride powder, and europium nitride synthesized by nitriding metal europium in ammonia.
In order to obtain a compound represented by the composition formula: Eu0.008Ca0.992AlSiN3 (Table 1 shows parameters for designed composition, Table 2 shows designed composition (% by weight), and Table 3 shows a mixing composition of a raw powder), the silicon nitride powder, the aluminum nitride powder, the calcium nitride powder, and the europium nitride powder were weighed so as to be 33.8578% by weight, 29.6814% by weight, 35.4993% by weight, and 0.96147% by weight, respectively, followed by 30 minutes of mixing by means of an agate mortar and pestle. Thereafter, the resulting mixture was allowed to fall freely into a crucible made of boron nitride through a sieve of 500 μm to fill the crucible with the powder. The volume-filling rate of the powder was about 25%. In this connection, respective steps of weighing, mixing, and molding of the powders were all conducted in a globe box capable of maintaining a nitrogen atmosphere having a moisture content of 1 ppm or less and an oxygen content of 1 ppm or less.
The mixed powder was placed in a crucible made of boron nitride and set in a graphite resistive heating-type electric furnace. The baking operations were conducted as follows: the baking atmosphere was first vacuumed by a diffusion pump, heated from room temperature to 800° C. at a rate of 500° C. per hour, and pressurized to 1 MPa by introducing nitrogen having a purity of 99.999% by volume at 800° C., and the temperature was elevated to 1800° C. at a rate of 500° C. per hour and held at 1800° C. for 2 hours.
After baking, the resulting baked product was roughly pulverized and then was pulverized by hand using a crucible and mortar made of silicon nitride sintered compact, followed by filtering through a sieve having a mesh of 30 μm. When the particle distribution was measured, the average particle size was found to be 15 μm.
The constitutive crystal phase of the resulting synthetic powder was identified according to the following procedure. First, in order to obtain pure CaAlSiN3 containing no M Element as a standard substance, the silicon nitride powder, the aluminum nitride powder, and the calcium nitride powder were weighed so as to be 34.088% by weight, 29.883% by weight, and 36.029% by weight, respectively, followed by 30 minutes of mixing by means of an agate mortar and pestle in a globe box. Then, the mixture was placed in a crucible made of boron nitride and set in a graphite resistive heating-type electric furnace. The baking operations were conducted as follows: the baking atmosphere was first vacuumed by a diffusion pump, heated from warm room to 800° C. at a rate of 500° C. per hour, and pressurized to 1 MPa by introducing nitrogen having a purity of 99.999% by volume at 800° C., and the temperature was elevated to 1800° C. at a rate of 500° C. per hour and held at 1800° C. for 2 hours. The synthesized sample was pulverized by means of an agate mortar and then measurement of powder X-ray diffraction was conducted using Kα line of Cu. As a result, the resulting chart shows a pattern illustrated in FIGS. 1-1 and the compound was judged to be a CaAlSiN3 crystal phase based on indexing shown in Table 4. The crystal phase is an orthorhombic system, which has lattice constants of a=9.8007(4) Å, b=5.6497(2) Å, and c=5.0627 (2) Å. A space group determined by convergent beam electron diffraction using TEM is Cmc21 (36th space group of International Tables for Crystallography). Furthermore, the atomic coordinate position of each element determined by the Rietveld analysis using the space group is as shown in Table 5. The measured intensity of X-ray diffraction and the calculated intensity computed by the Rietveld method from the atomic coordinates show a good coincidence as shown in Table 4.
Next, the synthesized compound represented by the composition formula: Eu0.008Ca0.992AlSiN3 was pulverized by means of an agate mortar and then measurement of powder X-ray diffraction was conducted using Kα line of Cu. As a result, the resulting chart is shown in FIGS. 1-2 and the compound was judged to be a CaAlSiN3 family crystal phase based on indexing shown in Table 4.
The composition analysis of the powder was conducted by the following method. First, 50 mg of the sample was placed in a platinum crucible and 0.5 g of sodium carbonate and 0.2 g of boric acid were added thereto, followed by heating and melting the whole. Thereafter, the melt was dissolved in 2 ml of hydrochloric acid to be a constant volume of 100 ml, whereby a solution for measurement: was prepared. By subjecting the liquid sample to ICP emission spectrometry, the amounts of Si, Al, Eu, and Ca in the powder sample were quantitatively determined. Moreover, 20 mg of the sample was charged into a Tin capsule, which was then placed in a nickel basket. Then, using TC-436 Model oxygen and nitrogen analyzer manufactured by LECO, oxygen and nitrogen in the powder sample were quantitatively determined. The results of the measurement were as follows: Eu: 0.86±0.01% by weight, Ca: 28.9±0.1% by weight, Si: 20.4±0.1% by weight, Al: 19.6±0.1% by weight, N, 28.3±0.2% by weight, O: 2.0±0.1% by weight. In comparison with the indicated % by weight in the designed composition shown in Table 2, an oxygen content is especially high. The reason therefor is attributed to impurity oxygen contained in silicon nitride, aluminum nitride, and calcium nitride, which were employed as raw materials. In this composition, the ratio of number of atoms of N and O, N/(0+N) corresponds to 0.942. The composition of the synthesized inorganic compound calculated from the analytical results of all the elements is EU0.0078Ca0.9922Si0.9997Al0.9996N2.782O0.172. In the invention, one wherein part of N is replaced with 0 is also included in the scope of the invention and, even in that case, a high-luminance red phosphor is obtained.
As a result of irradiation of the powder with a lamp emitting a light having a wavelength of 365 nm, emission of a red light was confirmed. As a result of measurement of emission spectrum (FIG. 4) and excitation spectrum (FIG. 5) of the powder using a fluorescence spectrophotometer, with regard to the peak wavelengths of the excitation and emission spectra (Table 6), it was found that the peak of the excitation spectrum was present at 449 nm and it was a phosphor having a peak at a red light of 653 nm in the emission spectrum with excitation at 449 nm. The emission intensity of the peak was 10655 counts. In this connection, since the count value varies depending on the measuring apparatus and conditions, the unit is an arbitrary unit. Moreover, the CIE chromaticity determined from the emission spectrum with excitation at 449 nm was red color of x=0.6699 and y=0.3263.







TABLE 1







Parameters for designed composition













M Element
A Element
D Element
E Element
X Element
















Eu
Mg
Ca
Sr
Ba
Si
Al
N












Example
a Value
b Value
c Value
d Value
e Value


















1
0.008
0
0.992
0
0
1
1
3


2
0.008
0
0
0
0.992
1
1
3


3
0.008
0
0.1984
0
0.7936
1
1
3


4
0.008
0
0.3968
0
0.5952
1
1
3


5
0.008
0
0.5952
0
0.3968
1
1
3


6
0.008
0
0.7936
0
0.1984
1
1
3


7
0.008
0
0.8928
0
0.0992
1
1
3


8
0.008
0
0.8928
0.0992
0
1
1
3


9
0.008
0
0.7936
0.1984
0
1
1
3


10
0.008
0
0.6944
0.2976
0
1
1
3


11
0.008
0
0.5952
0.3968
0
1
1
3


12
0.008
0
0.496
0.496
0
1
1
3


13
0.008
0
0.3968
0.5952
0
1
1
3


14
0.008
0
0.1984
0.7936
0
1
1
3


15
0.008
0
0
0.992
0
1
1
3


16
0.008
0.0992
0.8928
0
0
1
1
3


17
0.008
0.1984
0.7936
0
0
1
1
3


18
0.008
0.2976
0.6944
0
0
1
1
3


19
0.008
0.3968
0.5952
0
0
1
1
3


20
0.008
0.496
0.496
0
0
1
1
3


21
0.008
0.5952
0.3968
0
0
1
1
3


22
0.008
0.6944
0.2976
0
0
1
1
3


23
0.008
0.7936
0.1984
0
0
1
1
3


24
0.008
0.8928
0.0992
0
0
1
1
3


25
0.008
0.992
0
0
0
1
1
3
















TABLE 2







Designed composition (% by weight)















Example
Eu
Mg
Ca
Sr
Ba
Si
Al
N


















1
0.88056
0
28.799
0
0
20.3393
19.544
30.4372


2
0.51833
0
0
0
58.0887
11.9724
11.5042
17.9163


3
0.56479
0
3.69436
0
50.6371
13.0457
12.5356
19.5225


4
0.62041
0
8.11634
0
41.7178
14.3304
13.77
21.4451


5
0.68818
0
13.5044
0
30.8499
15.8958
15.2742
23.7876


6
0.77257
0
20.2139
0
17.3165
17.8451
17.1473
26.7047


7
0.82304
0
24.2261
0
9.2238
19.0107
18.2673
28.449


8
0.85147
0
25.063
6.08788
0
19.6674
18.8984
29.4318


9
0.82425
0
21.5659
11.7864
0
19.0386
18.2941
28.4907


10
0.79871
0
18.2855
17.1319
0
18.4487
17.7273
27.608


11
0.7747
0
15.2022
22.156
0
17.8943
17.1945
26.7783


12
0.7521
0
12.2989
26.887
0
17.3722
16.6929
25.997


13
0.73078
0
9.56019
31.3497
0
16.8797
16.2196
25.26


14
0.69157
0
4.52361
39.5568
0
15.974
15.3494
23.9047


15
0.65635
0
0
46.928
0
15.1605
14.5677
22.6874


16
0.89065
1.76643
26.2163
0
0
20.5725
19.768
30.7862


17
0.90098
3.57383
23.5736
0
0
20.8111
19.9973
31.1432


18
0.91155
5.42365
20.869
0
0
21.0553
20.2319
31.5086


19
0.92238
7.3174
18.1001
0
0
21.3052
20.4722
31.8828


20
0.93346
9.25666
15.2646
0
0
21.5612
20.7181
32.2659


21
0.94481
11.2431
12.3602
0
0
21.8235
20.9701
32.6583


22
0.95645
13.2784
9.3843
0
0
22.0922
21.2283
33.0604


23
0.96837
15.3645
6.33418
0
0
22.3676
21.4929
33.4725


24
0.98059
17.5033
3.20707
0
0
22.6499
21.7642
33.895


25
0.99313
19.6967
0
0
0
22.9394
22.0425
34.3283
















TABLE 3







Mixing composition (% by weight)














Example
EuN
Mg3N2
Ca3N2
Sr3N2
Ba3N2
Si3N4
AlN

















1
0.96147
0
35.4993
0
0
33.8578
29.6814


2
0.56601
0
0
0
62.0287
19.932
17.4733


3
0.61675
0
4.55431
0
54.0709
21.7185
19.0395


4
0.67747
0
10.0054
0
44.546
23.8569
20.9142


5
0.75146
0
16.6472
0
32.9406
26.4624
23.1982


6
0.84359
0
24.9176
0
18.4896
29.7068
26.0424


7
0.89868
0
29.863
0
9.84853
31.6467
27.7431


8
0.92972
0
30.8943
6.73497
0
32.7397
28.7012


9
0.9
0
26.5838
13.0394
0
31.6931
27.7837


10
0.87212
0
22.5403
18.9531
0
30.7114
26.9231


11
0.84592
0
18.7397
24.5116
0
29.7886
26.1142


12
0.82124
0
15.1609
29.7457
0
28.9197
25.3524


13
0.79797
0
11.785
34.6832
0
28.1
24.6339


14
0.75516
0
5.57638
43.7635
0
26.5926
23.3124


15
0.71671
0
0
51.9191
0
25.2387
22.1255


16
0.97249
2.44443
32.3156
0
0
34.2459
30.0216


17
0.98377
4.94555
29.058
0
0
34.6429
30.3697


18
0.99531
7.50535
25.724
0
0
35.0493
30.726


19
1.00712
10.1259
22.3109
0
0
35.4654
31.0907


20
1.01922
12.8095
18.8158
0
0
35.8914
31.4642


21
1.03161
15.5582
15.2356
0
0
36.3278
31.8467


22
1.04431
18.3747
11.5674
0
0
36.7749
32.2387


23
1.05732
21.2613
7.80768
0
0
37.2332
32.6404


24
1.07067
24.2208
3.9531
0
0
37.7031
33.0523


25
1.08435
27.256
0
0
0
38.1849
33.4748


















TABLE 4








Observed
Calculated



intensity
intensity












Peak
Indices
2θ
Spacing
arbitrary
arbitrary














No.
h
k
l
degree
Å
unit
unit










Results of X-ray diffraction (No. 1)














1
2
0
0
18.088
4.90033
1129
360


2
1
1
0
18.109
4.89464
3960
1242


3
2
0
0
18.133
4.90033
569
178


4
1
1
0
18.154
4.89464
1993
614


5
1
1
1
25.288
3.51896
3917
5137


6
1
1
1
25.352
3.51896
1962
2539


7
3
1
0
31.61
2.82811
72213
68028


8
0
2
0
31.648
2.82483
38700
36445


9
3
1
0
31.691
2.82811
35723
33624


10
0
2
0
31.729
2.82483
19158
18014


11
0
0
2
35.431
2.53137
75596
78817


12
0
0
2
35.522
2.53137
37579
39097


13
3
1
1
36.357
2.469
100000
101156


14
0
2
1
36.391
2.4668
56283
56923


15
3
1
1
36.451
2.469
49334
49816


16
0
2
1
36.484
2.4668
27873
28187


17
4
0
0
36.647
2.45017
15089
15187


18
2
2
0
36.691
2.44732
11430
11483


19
4
0
0
36.741
2.45017
7481
7507


20
2
2
0
36.785
2.44732
5661
5676


21
2
0
2
40.058
2.24902
5403
5599


22
1
1
2
40.068
2.24847
76
79


23
2
0
2
40.162
2.24902
2678
2767


24
1
1
2
40.172
2.24847
38
39


25
2
2
1
40.924
2.20339
14316
13616


26
2
2
1
41.031
2.20339
7123
6730


27
3
1
2
48.207
1.88616
21363
21434


28
0
2
2
48.233
1.88519
19002
19072


29
3
1
2
48.334
1.88616
10584
10591


30
0
2
2
48.361
1.88519
9407
9424


31
5
1
0
49.159
1.85184
2572
2513


32
4
2
0
49.185
1.85092
4906
4795


33
1
3
0
49.228
1.84939
253
239


34
5
1
0
49.289
1.85184
1346
1242


35
4
2
0
49.315
1.85092
2565
2369


36
1
3
0
49.359
1.84939
130
118


37
4
0
2
51.892
1.76054
6201
6580


38
2
2
2
51.926
1.75948
6187
6564


39
4
0
2
51.031
1.76054
3075
3251


40
2
2
2
52.064
1.75948
3078
3243


41
5
1
1
52.579
1.73915
2042
2153


42
4
2
1
52.604
1.73839
188
199


43
1
3
1
52.645
1.73712
282
298


44
5
1
1
52.72
1.73915
1002
1064


45
4
2
1
52.745
1.73839
92
98


46
1
3
1
52.786
1.73712
139
147


47
6
0
0
56.272
1.63344
17721
17283


48
3
3
0
56.344
1.63155
33576
32772


49
6
0
0
56.425
1.63344
8757
8541


50
3
3
0
56.496
1.63155
16569
16195







Results of X-ray diffraction (No. 2)














51
1
1
3
57.738
1.59541
771
461


52
1
1
3
57.895
1.59541
447
228


53
3
3
1
59.475
1.5529
987
445


54
3
3
1
59.638
1.5529
504
220


55
5
1
2
62.045
1.4946
421
460


56
4
2
2
62.068
1.49412
3824
4174


57
1
3
2
62.105
1.49331
518
571


58
5
1
2
62.217
1.4946
209
227


59
4
2
2
62.239
1.49412
1886
2063


60
1
3
2
62.276
1.49331
257
282


61
3
1
3
64.218
1.44918
25890
27958


62
0
2
3
64.239
1.44874
19133
20597


63
3
1
3
64.396
1.44918
12851
13816


64
0
2
3
64.418
1.44874
9441
10178


65
6
2
0
66.013
1.41406
6643
6534


66
0
4
0
66.099
1.41242
2793
2737


67
6
2
0
66.198
1.41406
3327
3229


68
0
4
0
66.284
1.41242
1385
1315


69
2
2
3
67.344
1.3893
3814
3509


70
2
2
3
67.534
1.3893
1869
1735


71
6
0
2
68.281
1.3725
18466
17968


72
3
3
2
68.345
1.37138
27397
26670


73
6
0
2
68.474
1.3725
9086
8881


74
3
3
2
68.538
1.37138
13419
13182


75
6
2
1
68.885
1.36193
22014
21698


76
0
4
1
68.97
1.36046
11088
10930


77
7
1
0
69.056
1.35899
827
815


78
6
2
1
69.081
1.36193
10883
10725


79
5
3
0
69.112
1.35802
573
564


80
2
4
0
69.161
1.35717
4360
4307


81
0
4
1
69.166
1.36046
5470
5403


82
7
1
0
69.252
1.35899
409
403


83
5
3
0
69.308
1.35802
283
279


84
2
4
0
69.358
1.35717
2165
2129


85
7
1
1
71.871
1.31252
263
170


86
5
3
1
71.926
1.31165
684
445


87
2
4
1
71.974
1.31088
810
520


88
7
1
1
72.077
1.31252
132
84


89
5
3
1
72.133
1.31165
345
220


90
2
4
1
72.181
1.31088
399
257


91
0
0
4
74.975
1.26568
3881
3841


92
0
0
4
75.194
1.26568
1960
1899


93
5
1
3
76.274
1.24734
1812
1659


94
4
2
3
76.294
1.23705
865
798


95
1
3
3
76.328
1.24659
516
478


96
5
1
3
76.497
1.24734
826
820


97
4
2
3
76.518
1.24705
403
395


98
1
3
3
76.552
1.24659
241
237


99
6
2
2
77.212
1.2345
6989
7316


100
0
4
2
77.293
1.23341
1114
1179







Results of X-ray diffraction (No. 3)














101
6
2
2
77.439
1.2345
3384
3619


102
0
4
2
77.521
1.23341
542
583


103
2
0
4
77.888
1.22547
2080
2260


104
1
1
4
77.895
1.22538
237
253


105
8
0
0
77.917
1.22508
32
35


106
4
4
0
78.025
1.22366
144
155


107
2
0
4
78.118
1.22547
1016
1118


108
1
1
4
78.125
1.22538
113
125


109
8
0
0
78.148
1.22508
16
17


110
4
4
0
78.256
1.22366
69
77


111
7
1
2
80.08
1.19735
671
762


112
5
3
2
80.134
1.19668
45
51


113
2
4
2
80.18
1.1961
2092
2383


114
7
1
2
80.32
1.19735
332
377


115
5
3
2
80.373
1.19668
22
25


116
2
4
2
80.42
1.1961
1032
1179


117
4
4
1
80.724
1.18941
1023
1169


118
4
4
1
80.966
1.18941
504
579


119
3
3
3
82.095
1.17299
566
560


120
3
3
3
82.343
1.17299
249
277


121
3
1
4
83.634
1.15527
2395
2418


122
0
2
4
83.654
1.15504
2611
2637


123
3
1
4
83.889
1.15527
1191
1197


124
0
2
4
83.909
1.15504
1309
1306


125
4
0
4
86.47
1.12451
531
492


126
2
2
4
86.496
1.12423
1172
1090


127
8
2
0
86.525
1.12394
278
258


128
7
3
0
86.558
1.12359
934
864


129
1
5
0
86.663
1.1225
737
688


130
4
0
4
86.738
1.12451
262
244


131
2
2
4
86.765
1.12423
585
540


132
8
2
0
86.793
1.12394
139
128


133
7
3
0
86.826
1.12359
467
428


134
1
5
0
86.932
1.1225
367
341


135
8
0
2
88.617
1.10273
102
99


136
4
4
2
88.722
1.10169
1094
1054


137
8
0
2
88.895
1.10273
50
49


138
4
4
2
89.001
1.10169
525
523


139
8
2
1
89.18
1.09723
495
480


140
7
3
1
89.213
1.09691
551
552


141
1
5
1
89.318
1.09588
123
123


142
8
2
1
89.461
1.09723
239
238


143
7
3
1
89.494
1.09691
271
274


144
1
5
1
89.6
1.09588
60
61


145
6
2
3
90.581
1.08386
8698
8736


146
0
4
3
90.66
1.08312
4187
4201


147
6
2
3
90.869
1.08386
4305
4332


148
0
4
3
90.949
1.08312
2067
2083


149
9
1
0
92.171
1.06928
921
787


150
6
4
0
92.269
1.06839
820
696







Results of X-ray diffraction (No. 4)














151
3
5
0
92.329
1.06786
846
709


152
9
1
0
92.467
1.06928
466
390


153
6
4
0
92.566
1.06839
403
346


154
3
5
0
92.626
1.06786
407
352


155
7
1
3
93.395
1.05845
882
812


156
5
3
3
93.448
1.058
1111
1042


157
2
4
3
93.494
1.05759
575
533


158
7
1
3
93.697
1.05845
439
403


159
5
3
3
93.75
1.058
557
517


160
2
4
3
93.797
1.05759
286
264


161
9
1
1
94.828
1.0462
8091
7983


162
6
4
1
94.928
1.04537
8273
8175


163
5
1
4
94.979
1.04494
392
387


164
3
5
1
94.987
1.04487
8587
8469


165
4
2
4
94.999
1.04477
1156
1143


166
1
3
4
95.032
1.0445
609
602


167
9
1
1
95.139
1.0462
4016
3962


168
6
4
1
92.238
1.04537
4108
4058


169
5
1
4
95.29
1.04494
195
192


170
3
5
1
95.298
1.04487
4269
4204


171
4
2
4
95.31
1.04477
575
567


172
1
3
4
95.344
1.0445
304
299


173
8
2
2
97.156
1.02724
533
515


174
7
3
2
97.189
1.02697
983
946


175
1
5
2
97.296
1.02613
878
840


176
8
2
2
97.479
1.02724
264
256


177
7
3
2
97.513
1.02697
482
470


178
1
5
2
97.62
1.02613
426
417


179
6
0
4
100.691
1.00049
5749
5826


180
3
3
4
100.751
1.00005
7565
7696


181
6
0
4
101.035
1.00049
2904
2897


182
3
3
4
101.096
1.00005
3864
3826


183
1
1
5
101.945
0.99155
99
95


184
4
4
3
102.075
0.99064
700
665


185
1
1
5
102.297
0.99155
50
47


186
4
4
3
102.428
0.99064
353
331


187
9
1
2
102.889
0.98501
2904
2773


188
6
4
2
102.99
0.98431
1613
1539


189
3
5
2
103.051
0.9839
2352
2255


190
9
1
2
103.247
0.98501
1414
1379


191
6
4
2
103.349
0.98431
774
766


192
3
5
2
103.41
0.9839
1122
1122


193
10
0
0
103.617
0.98007
899
903


194
5
5
0
103.786
0.97893
803
806


195
10
0
0
103.979
0.98007
451
449


196
5
5
0
104.15
0.97893
411
401


197
5
5
1
106.535
0.96113
323
378


198
5
5
1
106.917
0.96113
183
188


199
3
1
5
107.807
0.95329
6210
6468


200
0
2
5
107.827
0.95316
3757
3932







Results of X-ray diffraction (No. 5)














201
3
1
5
108.198
0.95329
3120
3223


202
0
2
5
108.219
0.95316
1888
1959


203
6
2
4
109.525
0.94308
3209
2974


204
9
3
0
109.591
0.9427
3570
3280


205
0
4
4
109.609
0.9426
656
602


206
0
6
0
109.779
0.94161
1454
1338


207
6
2
4
109.93
0.94308
1622
1483


208
9
3
0
109.995
0.9427
1792
1636


209
0
4
4
110.014
0.9426
329
300


210
0
6
0
110.185
0.94161
731
667


211
2
2
5
110.828
0.93563
247
223


212
8
2
3
110.859
0.93546
1336
1210


213
7
3
3
110.894
0.93526
103
93


214
1
5
3
111.007
0.93463
519
457


215
2
2
5
111.242
0.93563
119
111


216
8
2
3
111.273
0.93546
647
604


217
7
3
3
111.308
0.93526
49
46


218
1
5
3
111.422
0.93463
246
228


219
9
3
1
112.432
0.92677
457
453


220
7
1
4
112.538
0.9262
96
97


221
10
2
0
112.59
0.92592
528
532


222
5
3
4
112.595
0.9259
832
826


223
0
6
1
112.625
0.92574
381
385


224
2
4
4
112.645
0.92563
174
173


225
8
4
0
112.676
0.92546
1400
1394


226
2
6
0
112.819
0.92469
115
117


227
9
3
1
112.859
0.92677
222
226


228
7
1
4
112.966
0.9262
47
48


229
10
2
0
113.018
0.92592
261
265


230
5
3
4
113.023
0.9259
405
412


231
0
6
1
113.053
0.92574
188
192


232
2
4
4
113.074
0.92563
86
87


233
8
4
0
113.105
0.92546
688
696


234
2
6
0
113.249
0.92469
56
59


235
10
0
2
114.874
0.91396
1273
1144


236
5
5
2
115.055
0.91303
1086
961


237
10
0
2
115.321
0.91396
627
571


238
10
2
1
115.495
0.91081
149
143


239
5
5
2
115.504
0.91303
501
480


240
8
4
1
115.583
0.91038
71
69


241
2
6
1
115.729
0.90965
825
800


242
10
2
1
115.948
0.91081
76
71


243
8
4
1
116.036
0.91038
36
34


244
2
6
1
116.184
0.90965
418
400


245
9
1
3
117.036
0.90323
3785
3707


246
6
4
3
117.147
0.9027
6351
6249


247
3
5
3
117.214
0.90238
8809
8688


248
9
1
3
117.503
0.90323
1876
1854


249
6
4
3
117.615
0.9027
3153
3125


250
3
5
3
117.682
0.90238
4393
4345







Results of X-ray diffraction (No. 6)














251
5
1
5
120.23
0.88842
190
173


252
4
2
5
120.253
0.88831
1117
1030


253
1
3
5
120.291
0.88814
215
197


254
5
1
5
120.727
0.88842
92
87


255
4
2
5
120.751
0.88831
556
516


256
1
3
5
120.789
0.88814
107
99


257
9
3
2
121.365
0.88343
9276
8712


258
0
6
2
121.573
0.88253
3149
2999


259
9
3
2
121.874
0.88343
4581
4365


260
0
6
2
122.085
0.88253
1548
1503


261
8
0
4
122.102
0.88027
825
792


262
11
1
0
122.144
0.88009
48
46


263
4
4
4
122.227
0.87974
1161
1113


264
7
5
0
122.331
0.8793
55
53


265
4
6
0
122.416
0.87894
35
34


266
8
0
4
122.619
0.88027
411
397


267
11
1
0
122.661
0.88009
23
23


268
4
4
4
122.745
0.87974
570
558


269
7
5
0
122.85
0.8793
27
26


270
4
6
0
122.937
0.87894
17
17


271
10
2
2
124.703
0.86958
1189
1160


272
8
4
2
124.8
0.86919
1867
1838


273
2
6
2
124.96
0.86856
465
456


274
10
2
2
125.249
0.86958
604
582


275
11
1
1
125.334
0.86709
855
833


276
8
4
2
125.347
0.86919
947
923


277
2
6
2
125.509
0.86856
234
229


278
7
5
1
125.528
0.86633
30
29


279
4
6
1
125.617
0.86599
2025
1984


280
11
1
1
125.888
0.86709
430
418


281
7
5
1
126.084
0.86633
15
15


282
4
6
1
126.174
0.86599
1035
996


283
3
3
5
127.101
0.86033
236
232


284
3
3
5
127.677
0.86033
128
117
















TABLE 5





Data of crystal structure of CaAlSiN3







CaAlSiN3


Space Group (#36) Cmc21


Lattice constants (Å)












a
b
c





9.8007 (4)
5.6497 (2)
5.0627 (2)

















Site
x
y
z






Si/Al
8 (b)
0.1734 (2)
0.1565 (3)
0.0504 (4)



N1
8 (b)
0.2108 (4)
0.1205 (8)
0.3975 (2)



N2
4 (a)
0
0.2453 (7)
 0.0000 (10)



Ca
4 (a)
0
0.3144 (3)
0.5283










SiN2O


Space Group (#36) Cmc21


Lattice constants (Å)












a
b
c





8.8717
5.4909
4.8504

















Site
x
y
z






Si/Al
8 (b)
0.1767
0.1511
0.0515



N
8 (b)
0.2191
0.1228
0.3967



O
4 (a)
0
0.2127
0
















TABLE 6







Peak wavelength and intensity of excitation


emission spectra












Emission
Emission
Excitation
Excitation



intensity
wavelength
intensity
wavelength


Example
arbitrary unit
nm
arbitrary unit
nm














1
10655
653
10595
449


2
622
600
617
449


3
2358
655
2336
449


4
4492
655
4471
449


5
5985
655
5975
449


6
6525
654
6464
449


7
6796
654
6748
449


8
8457
654
8347
449


9
8384
650
8278
449


10
7591
650
7486
449


11
7368
645
7264
449


12
7924
641
7834
449


13
8019
637
7920
449


14
8174
629
8023
449


15
1554
679
1527
401


16
8843
657
8779
449


17
5644
658
5592
449


18
6189
658
6199
449


19
5332
657
5261
449


20
5152
661
5114
449


21
4204
663
4177
449


22
3719
667
3710
449


23
3800
664
3833
449


24
2090
679
2097
449


25
322
679
326
453









Comparative Example 1
Using the raw powders described in Example 1, in order to obtain pure CaAlSiN3 containing no M Element, the silicon nitride powder, the aluminum nitride powder, and the calcium nitride powder were weighed so as to be 34.088% by weight, 29.883% by weight, and 36.029% by weight, respectively, and a powder was prepared in the same manner as in Example 1. According to the measurement of X-ray diffraction, it was confirmed that the synthesized powder was CaAlSiN3. When excitation and emission spectra of the synthesized inorganic compound were measured, any remarkable emission peak was not observed in the range of 570 nm to 700 nm.
Examples 2 to 7
As Examples 2 to 7 were prepared inorganic compounds having a composition in which part or all of Ca was replaced with Ba.
The inorganic compounds were prepared in the same manner as in Example 1 with the exception of the compositions shown in Tables 1, 2, and 3. According to the measurement of X-ray diffraction, it was confirmed that the synthesized powders were inorganic compounds having the same crystal structure as that of CaAlSiN3. When excitation and emission spectra of the synthesized inorganic compound were measured, as shown in FIGS. 4 and 5, and Table 6, it was confirmed that they were red phosphors having an emission peak in the range of 570 nm to 700 nm, which were excited with an ultraviolet ray or a visible light of 350 nm to 600 nm. Incidentally, since emission luminance decreases as an added amount of Ba increases, a composition in the region where the added amount of Ba is small is preferred.
Examples 8 to 15
As Examples 8 to 15 were prepared inorganic compounds having a composition in which part or all of Ca was replaced with Sr.
Phosphors were prepared in the same manner as in Example 1 with the exception of the compositions shown in Tables 1, 2, and 3. According to the measurement of X-ray diffraction, it was confirmed that the synthesized powders were inorganic compounds having the same crystal structure as that of CaAlSiN3. When excitation and emission spectra of the synthesized inorganic compound. were measured, as shown in FIGS. 6 and 7 (Examples 8 to 11), FIGS. 8 and 9 (Examples 12 to 15), and Table 6, it was confirmed that they were red phosphors having an emission peak in the range of 570 nm to 700 nm, which were excited with an ultraviolet ray or a visible light of 350 nm to 600 nm. Incidentally, emission luminance decreases as an added amount of Sr increases, but the wavelength of the emission peak shifts to a shorter wavelength side as compared with the addition of Ca alone. Therefore, in the case that it is desired to obtain a phosphor having a peak wavelength in the range of 600 nm to 650 nm, it is effective to replace part of Ca with Sr.
Examples 16 to 25
As Examples 16 to 25 were prepared inorganic compounds having a composition in which part or all of Ca was replaced with Mg.
Phosphors were prepared in the same manner as in Example 1 with the exception of the compositions shown in Tables 1, 2, and 3. According to the measurement of X-ray diffraction, it was confirmed that the synthesized powders were inorganic compounds having the same crystal structure as that of CaAlSiN3. When excitation and emission spectra of the synthesized inorganic compound were measured, as shown in FIGS. 10 and 11, and Table 6, it was confirmed that they were red phosphors having an emission peak in the range of 570 nm to 700 nm, which were excited with an ultraviolet ray or a visible light of 350 nm to 600 nm. Incidentally, since emission luminance decreases as an added amount of Mg increases, a composition in the region where the added amount of Mg is small is preferred.
Examples 26 to 30
As Examples 26 to 30 were prepared inorganic compounds having a composition in which part of N was replaced with 0. In this case, since valence number is different between N and O, simple replacement does not result in neutrality of the total charge. Thus, the composition:

Ca6Si6-xAl6+xOxN18-x(0<x≦3)

was investigated, which is a composition in which Si—N is replaced with Al—O.

Phosphors were prepared in the same manner as in Example 1 with the exception of the compositions shown in Tables 7 and 8. According to the measurement of X-ray diffraction, it was confirmed that the synthesized powders were inorganic compounds having the same crystal structure as that of CaAlSiN3. When excitation and emission spectra of the synthesized inorganic compound were measured, as shown in FIGS. 12 and 13, it was confirmed that they were red phosphors having an emission peak in the range of 570 nm to 700 nm, which were excited with an ultraviolet ray or a visible light of 350 nm to 600 nm. Incidentally, since emission luminance decreases as an added amount of oxygen increases, a composition in the region where the added amount of oxygen is small is preferred.







TABLE 7







Parameters for designed composition













M Element
A Element
D Element
E Element
X Element














Eu
Ca
Si
Al
O
N












Example
a Value
b Value
c Value
d Value
e Value
















26
0.008
0.992
0.916667
1.083333
0.083333
2.919333


27
0.008
0.992
0.833333
1.166667
0.166667
2.836


28
0.008
0.992
0.75
1.25
0.25
2.752667


29
0.008
0.992
0.666667
1.333333
0.333333
2.669333


30
0.008
0.992
0.5
1.5
0.5
2.502667
















TABLE 8







Mixing composition (% by weight)












Example
Si3N4
AIN
Al203
Ca3N2
EuN















26
31.02
30.489
2.05
35.48
0.961


27
28.184
31.297
4.097
35.461
0.96


28
25.352
32.103
6.143
35.442
0.96


29
22.523
32.908
8.186
35.423
0.959


30
16.874
34.517
12.266
35.385
0.958









Examples 31 to 37
Using the same raw powders as in Example 1, in order to obtain inorganic compounds (showing mixing compositions of the raw powders in Table 9 and composition parameters in Table 10), the silicon nitride powder, the aluminum nitride powder, the calcium nitride powder, and the europium nitride powder were weighed, followed by 30 minutes of mixing by means of an agate mortar and pestle. Thereafter, the resulting mixture was molded using a mold by applying a pressure of 20 MPa to form a molded article having a diameter of 12 mm and a thickness of 5 mm. In this connection, respective steps of weighing, mixing, and molding of the powders were all conducted in a globe box capable of maintaining a nitrogen atmosphere having a moisture content of 1 ppm or less and an oxygen content of 1 ppm or less.
The molded article was placed in a crucible made of boron nitride and set in a graphite resistive heating-type electric furnace. The baking operations were conducted as follows: the baking atmosphere was first vacuumed by a diffusion pump, heated from warm room to 800° C. at a rate of 500° C. per hour, and pressurized to 1 MPa by introducing nitrogen having a purity of 99.999% by volume at 800° C., and the temperature was elevated to 1800° C. at a rate of 500° C. per hour and held at 1800° C. for 2 hours.
After baking, as a result of identification of constitutive crystal phase of the resulting sintered compact, it was judged to be a CaAlSiN3 family crystal phase. As a result of irradiation of the powder with a lamp emitting a light having a wavelength of 365 nm, it was confirmed that it emits a red light. When excitation spectrum and emission spectrum of the powder were measured using a fluorescence spectrophotometer, as shown in Table 11, it was confirmed that it was a red phosphor having an emission peak in the range of 570 nm to 700 nm, which was excited with an ultraviolet ray or a visible light of 350 nm to 600 nm. Incidentally, since the measurement in these Examples was conducted using an apparatus different from that used in other Examples, the count values can be compared only within the range of Examples 31 to 37.







TABLE 9







Mixing composition of raw powder (unit: % by weight)












Si3N4
AlN
Ca3N2
EuN














Example 31
34.07348
29.870475
35.995571
0.060475


Example 32
34.059016
29.857795
35.962291
0.120898


Example 33
34.030124
29.832467
35.895818
0.241591


Example 34
33.518333
29.383806
34.718285
2.379577


Example 35
33.185606
29.092121
33.952744
3.769529


Example 36
32.434351
28.433534
32.224251
6.907864


Example 37
31.418284
27.542801
29.886478
11.152437
















TABLE 10







Parameters for designed composition













a(Eu)
b(Ca)
c(Si)
d(Al)
e(N)

















Example 31
0.0005
0.9995
1
1
3



Example 32
0.001
0.999
1
1
3



Example 33
0.002
0.998
1
1
3



Example 34
0.02
0.98
1
1
3



Example 35
0.032
0.968
1
1
3



Example 36
0.06
0.94
1
1
3



Example 37
0.1
0.9
1
1
3
















TABLE 11







Peak wavelength and intensity of excitation and


emission spectra on fluorescence measurement










Excitation spectrum
Emission spectrum












Peak
Intensity
Peak
Intensity



wavelength
arbitrary
wavelength
arbitrary



nm
unit
nm
unit














Example 31
479.6
387.322
609.2
391.066


Example 32
472.8
374.967
609.2
375.33


Example 33
480
427.41
612.6
428.854


Example 34
538
412.605
626.8
411.394


Example 35
546.4
414.434
629.2
413.009


Example 36
549.8
181.127
638.8
180.981


Example 37
549.4
89.023
644.4
92.763









Examples 38 to 56 and 60 to 76
As Examples 38 to 56 and 60 to 76 were prepared inorganic compounds having compositions in which c, d, and e parameters in the EuaCabSicAldNe composition were changed.
Phosphors were prepared in the same manner as in Example 1 with the exception of the compositions shown in Tables 12 and 13. According to the measurement of X-ray diffraction, it was confirmed that; the synthesized powders were powders containing inorganic compounds having the same crystal structure as that of CaAlSiN3. When excitation and emission spectra of the synthesized inorganic compound were measured, as shown in Table 14, it was confirmed that they were red phosphors having an emission peak in the range of 570 nm to 700 nm, which were excited with an ultraviolet ray or a visible light of 350 nm to 600 nm.







TABLE 12







Parameters for designed composition













a Value
b Value





Example
(Eu)
(Ca)
c Value (Si)
d Value (Al)
e Value (N)















38
0.002
0.998
1
1
3


39
0.004
0.996
1
1
3


40
0.008
0.992
1
1
3


41
0.01
0.99
1
1
3


42
0.06
0.94
1
1
3


43
0.2
0.8
1
1
3


44
0.0107
0.9893
1
2
3


45
0.0133
0.9867
1
3
3


46
0.016
0.984
1
4
3


47
0.0187
0.9813
1
5
3


48
0.0213
0.9787
1
6
3


49
0.0107
0.9893
2
1
3


50
0.0133
0.9867
2
2
3


51
0.016
0.984
2
3
3


52
0.0187
0.9813
2
4
3


53
0.0213
0.9787
2
5
3


54
0.024
0.976
2
6
3


55
0.0133
0.9867
3
1
3


56
0.016
0.984
4
1
3


60
0.016
0.984
3
2
3


61
0.019
0.981
3
3
3


62
0.013
2.987
1
1
3


63
0.013
1.987
2
1
3


64
0.016
2.984
2
1
3


65
0.016
1.984
3
1
3


66
0.019
2.981
3
1
3


67
0.013
1.987
1
2
3


68
0.016
2.984
1
2
3


69
0.019
2.981
2
2
3


70
0.019
1.981
3
2
3


71
0.021
2.979
3
2
3


72
0.016
1.984
1
3
3


73
0.019
2.981
1
3
3


74
0.019
1.981
2
3
3


75
0.021
2.979
2
3
3


76
0.021
1.979
3
3
3
















TABLE 13







Mixing composition of raw powder (unit: % by weight)











Example
Si3N4
AlN
Ca3N2
EuN














38
34.01
29.81
35.94
0.24


39
33.925
29.74
35.855
0.48


40
33.765
29.595
35.68
0.96


41
33.685
29.525
35.595
1.195


42
31.785
27.86
33.59
6.77


43
27.45
24.06
29.01
19.485


44
25.99
45.56
27.465
0.985


45
21.125
55.55
22.325
1


46
17.795
62.39
18.805
1.01


47
15.37
67.365
16.245
1.02


48
13.53
71.15
14.295
1.025


49
50.365
22.07
26.61
0.955


50
41.175
36.09
21.755
0.975


51
34.825
45.785
18.4
0.99


52
30.17
52.89
15.94
1


53
26.615
58.32
14.06
1.01


54
23.805
62.6
12.58
1.015


55
60.235
17.6
21.22
0.95


56
66.775
14.635
17.64
0.95


60
51.135
29.88
18.015
0.97


61
44.425
38.94
15.65
0.98


62
19.63
17.205
62.235
0.93


63
39.705
17.4
41.96
0.94


64
32.765
14.36
51.94
0.93


65
49.61
14.495
34.955
0.94


66
42.175
12.325
44.57
0.93


67
20.35
35.675
43.01
0.965


68
16.72
29.315
53.015
0.95


69
28.615
25.08
45.36
0.95


70
43.27
25.285
30.485
0.955


71
37.505
21.915
39.635
0.945


72
17.24
45.34
36.44
0.98


73
14.565
38.295
46.175
0.965


74
29.37
38.615
31.04
0.975


75
25.395
33.39
40.255
0.96


76
38.37
33.63
27.03
0.97
















TABLE 14







Peak wavelength of excitation and emission spectra


on fluorescence measurement










Excitation spectrum
Emission spectrum












Peak
Strength
Peak
Intensity



wavelength
arbitrary
wavelength
arbitrary


Example
nm
unit
nm
unit














38
449
8461
653
8479


39
449
7782
650
7832


40
449
8470
654
8551


41
449
9725
658
9762


42
449
6171
679
6182


43
449
1279
697
1245


44
449
7616
650
7763


45
449
7796
653
7854


46
449
6635
653
6685


47
449
6106
654
6149


48
449
5857
654
5907


49
333
5168
636
5211


50
332
4271
641
4342


51
330
4004
642
4046


52
335
3903
645
3954


53
335
3638
648
3703


54
337
3776
649
3799


55
316
2314
601
2348


56
407
1782
587
1906


60
412
4304
616
4330


61
409
4080
607
4099


62
467
3130
649
3135


63
322
2461
648
2461


64
449
1961
643
1996


65
316
3003
620
3003


66
319
3714
660
3714


67
449
4534
650
4586


68
467
3072
647
3067


69
449
6422
650
6426


70
449
7785
649
7856


71
449
4195
650
4179


72
449
4102
650
4095


73
461
2696
649
2693


74
449
9023
654
9146


75
450
5117
650
5180


76
322
6538
649
6538









Examples 77 to 84
As Examples 77 to 84 were prepared inorganic compounds having compositions in which D, E, and X Elements in the EUaCabDcEdXe composition were changed.
Phosphors were prepared in the same manner as in Example 1 with the exception of the compositions shown in Tables 15 and 16. According to the measurement of X-ray diffraction, it was confirmed that the synthesized powders were powders containing inorganic compounds having the same crystal structure as that of CaAlSiN3. When excitation and emission spectra of the synthesized inorganic compound were measured, as shown in Table 17, it was confirmed that they were red phosphors having an emission peak in the range of 570 nm to 700 nm, which were excited with an ultraviolet ray or a visible light of 350 nm to 600 nm.







TABLE 15







Parameters for designed composition













M
A
D
E
X



Element
Element
Element
Element
Element




















Eu
Ca
Si
Ge
Ti
Hf
Zr
Al
Y
Sc
N
O












Example
a Value
b Value
c Value
d Value
e Value






















77
0.008
0.992
1




0.95
0.05

3



78
0.008
0.992
1




0.9
0.1

3



79
0.008
0.992
1




0.8
0.2

3



80
0.008
0.992
0.95
0.05



1


3



81
0.008
0.992
1




0.97

0.03
3
0.045


82
0.008
0.992
0.97

0.03


1


3
0.06


83
0.008
0.992
0.95


0.05

1


3
0.1


84
0.008
0.992
0.97



0.03
1


3

















TABLE 16







Mixing composition of raw powder (unit: % by weight)












M Element
A Element
D Element
E Element

















Example
EuN
Ca3N2
Si3N4
Ge3N4
TiO2
HfO2
ZrN
AIN
YN
Sc2O3




















77
0.95
34.7
33.1




27.6
3.65



78
0.9
34
32.4




25.55
7.15



79
0.9
32.6
31.1




21.8
13.7



80
0.95
34.95
31.65
3.25



29.2




81
0.95
35.3
33.65




28.6

1.5


82
0.95
35.25
32.6

1.75


29.45




83
0.9
33.5
30.35


7.2

28




84
0.95
35
32.4



2.35
29.3
















TABLE 17







Peak wavelength and intensity of excitation and


emission spectra on fluorescence measurement










Excitation spectrum
Emission spectrum












Peak
Strength
Peak
Intensity



wavelength
arbitrary
wavelength
arbitrary


Example
nm
unit
nm
unit














77
449
6223
653
6380


78
449
4449
653
4565


79
449
3828
650
3937


80
449
2022
645
2048


81
449
5143
647
5481


82
450
2478
648
2534


83
449
3246
646
3303


84
449
8021
649
8050









Examples 85 to 92
As Examples 85 to 92 were prepared inorganic compounds having compositions in which M Element in the MaCabSicAld (N, O)e composition were changed.
Phosphors were prepared in the same manner as in Example 1 with the exception of the compositions shown in Tables 18 and 19. According to the measurement of X-ray diffraction, it was confirmed that the synthesized powders were powders containing inorganic compounds having the same crystal structure as that of CaAlSiN3. When excitation and emission spectra of the synthesized inorganic compound were measured, as shown in Table 20, is was confirmed that they were red phosphors having an emission peak in the range of 570 nm to 700 nm other than the phosphor of Example 89, which were excited with an ultraviolet ray or a visible light of 350 nm to 600 nm. In Example 89, emission having a peak wavelength of 550 nm was observed.







TABLE 18







Parameters for designed composition

















X



M Element
A Element
D Element
E Element
Element





















Mn
Ce
Sm
Eu
Tb
Dy
Er
Yb
Ca
Si
Al
N
O












Example
a Value
b Value
c Value
d Value
e Value























85
0.0027







0.9973
1
1
3
0.0027


86

0.0027






0.9973
1
1
3
0.0054


87


0.0027





0.9973
1
1
3
0.0041


88



0.0027




0.9973
1
1
3
0.0041


89




0.0027



0.9973
1
1
3
0.0047


90





0.0027


0.9973
1
1
3
0.0041


91






0.0027

0.9973
1
1
3
0.0041


92







0.0027
0.9973
1
1
3
0.0041
















TABLE 19







Mixing composition of raw powder (unit: % by weight)












M Element
A Element
D Element
E Element


















Example
MnCO3
CeO2
Sm2O3
Eu2O3
Tb4O7
Dy2O3
Er2O3
Yb2O3
Ca3N2
Si3N4
AIN





















85
0.22







35.95
34.01
29.82


86

0.33






35.91
33.97
29.78


87


0.34





35.91
33.97
29.78


88



0.341




35.91
33.97
29.78


89




0.36



35.9
33.96
29.77


90





0.36


35.9
33.97
29.78


91






0.37

35.9
33.96
29.77


92







0.38
35.89
33.96
29.77
















TABLE 20







Peak wavelength and intensity of excitation and


emission spectra on fluorescence measurement










Excitation spectrum
Emission spectrum












Peak
Strength
Peak
Intensity



wavelength
arbitrary
wavelength
arbitrary


Example
nm
unit
nm
unit














85
449
1629
631
1703


86
466
2453
616
2592


87
310
3344
651
3344


88
449
6933
641
7032


89
255
2550
550
2550


90
248
7459
580
7509


91
449
1572
631
1630


92
448
821
640
833









Example 101
As raw powders were used an Eu2O3 powder, a Ca3N2 powder having an oxygen content of 9% by mol which is represented by mol number of oxygen relative to the total mol number of nitrogen and oxygen, an Si3N4 powder having an oxygen content as above of 2% by mol, and an AlN powder having an oxygen content as above of 2% by mol. Respective powders were weighed so as to be the metal element composition ratio (mol ratio) of Eu:Ca:Al:Si=0.008:0.992:1:1 and mixed to obtain a raw mixed powder. The oxygen content represented by mol number of oxygen relative to the total mol number of nitrogen and oxygen in the raw mixed powder was 5% by mol. In this connection, the Ca3N2 powder is a powder obtained by allowing oxygen to exist using raw materials to be baked containing only a desired concentration of oxygen, the Si3N4 powder is a powder obtained by allowing oxygen to exist using raw materials to be baked containing only a desired concentration of oxygen, the AlN powder is a powder obtained by allowing oxygen to exist using raw materials to be baked containing only a desired concentration of oxygen.
The raw mixed powder was placed in a crucible made of boron nitride without compression so as to be a bulk density of 0.35 g/cm3 and was baked at 1600° C. for 10 hours in a highly pure nitrogen atmosphere containing an oxygen concentration of 10 ppm or less at a nitrogen pressure of 1.1 atm using an electric furnace. At this time, the oxygen existing ratio in the raw material at baking is 5% by mol based on the calculation from the oxygen concentration in each raw material and the mixing ratio of each raw material.
As a result of identification of the crystal phase formed in the resulting phosphor by powder X-ray diffraction method, it was confirmed that CaAlSiN3 family crystal phase was formed. When fluorescence properties of the phosphor were measured by excitation with a wavelength of 465 nm using a fluorescence spectrophotometer, the resulting phosphor showed a peak intensity of 128 in the case that the peak intensity of a commercially available yttrium aluminum garnet-based phosphor activated with Ce was regarded as 100, showing a high emission intensity, and a red light having a peak wavelength of 652 nm was observed. Moreover, 20 mg of the obtained phosphor sample was charged into a tin capsule, which was then placed in a nickel basket. Then, when the concentrations of oxygen and nitrogen in the powder sample were analyzed using a TC-436 Model oxygen and nitrogen analyzer manufactured by LECO, in the total of nitrogen and oxygen, it contained 94% by mol of nitrogen and 6% by mol of oxygen.
Example 102
A phosphor powder was obtained in the same manner as in Example 101 except that EuF3 was used instead of Eu2O3. The oxygen content represented by mol number of oxygen relative to the total mol number of nitrogen and oxygen in the raw mixed powder was 5% by mol. Moreover, the oxygen existing ratio in the raw material at baking is 5% by mol based on the calculation from the oxygen concentration in each raw material and the mixing ratio of each raw material.
As a result of identification of the crystal phase formed in the resulting phosphor by powder X-ray diffraction method, it was confirmed that CaAlSiN3 family crystal phase was formed. When fluorescence properties of the phosphor were measured by excitation with a wavelength of 465 nm using a fluorescence spectrophotometer, the resulting phosphor showed a peak intensity of 114 in the case that the peak intensity of a commercially available yttrium aluminum garnet-based phosphor activated with Ce was regarded as 100, showing a high emission intensity, and a red light having a peak wavelength of 650 nm was observed. Moreover, 20 mg of the obtained phosphor sample was charged into a tin capsule, which was then placed in a nickel basket. Then, when the concentrations of oxygen and nitrogen in the powder sample were analyzed using a TC-436 Mode: oxygen and nitrogen analyzer manufactured by LECO, in the total of nitrogen and oxygen, it contained 95% by mol of nitrogen and 5% by mol of oxygen.
Example 103
A phosphor powder was obtained in the same manner as in Example 101 except that EuN was used instead of Eu2O3 and the baking time was changed to 2 hours. The oxygen content represented by mol number of oxygen relative to the total mol number of nitrogen and oxygen in the raw mixed powder was 5% by mol. Moreover, the oxygen existing ratio in the raw material at baking is 5% by mol based on the calculation from the oxygen concentration in each raw material and the mixing ratio of each raw material.
As a result of identification of the crystal phase formed in the resulting phosphor by powder X-ray diffraction method, it was confirmed that CaAlSiN3 family crystal phase was formed. When fluorescence properties of the phosphor were measured by excitation with a wavelength of 465 nm using a fluorescence spectrophotometer, the resulting phosphor showed a peak intensity of 112 in the case that the peak intensity of a commercially available yttrium aluminum garnet-based phosphor activated with Ce was regarded as 100, showing a high emission intensity, and a red light having a peak wavelength of 649 nm was observed. Moreover, 20 mg of the obtained phosphor sample was charged into a tin capsule, which was then placed in a nickel basket. Then, when the concentrations of oxygen and nitrogen in the powder sample were analyzed using a TC-436 Model oxygen and nitrogen analyzer manufactured by LECO, in the total of nitrogen and oxygen, it contained 95% by mol of nitrogen and 5% by mol of oxygen.
Example 104
A phosphor powder was obtained in the same manner as in Example 101 except that EuN was used instead of Eu2O3, the nitrogen pressure was changed to 10 atm, and the baking time was changed to 2 hours. The oxygen content represented by mol number of oxygen relative to the total mol number of nitrogen and oxygen in the raw mixed powder was 5% by mol. Moreover, the oxygen existing ratio in the raw material at baking is 5% by mol based on the calculation from the oxygen concentration in each raw material and the mixing ratio of each raw material.
As a result of identification of the crystal phase formed in the resulting phosphor by powder X-ray diffraction method, it was confirmed that CaAlSiN3 family crystal phase was formed. When fluorescence properties of the phosphor were measured by excitation with a wavelength of 465 nm using a fluorescence spectrophotometer, the resulting phosphor showed a peak intensity of 109 in the case that the peak intensity of a commercially available yttrium aluminum garnet-based phosphor activated with Ce was regarded as 100, showing a high emission intensity, and a red light having a peak wavelength of 650 nm was observed. Moreover, 20 mg of the obtained phosphor sample was charged into a tin capsule, which was then placed in a nickel basket. Then, when the concentrations of oxygen and nitrogen in the powder sample were analyzed using a TC-436 Model oxygen and nitrogen analyzer manufactured by LECO, in the total of nitrogen and oxygen, it contained 95% by mol of nitrogen and 5% by mol of oxygen.
The results of Examples 101 to 104 are summarized in Table A.










TABLE A










Fluorescence properties



Baking conditions

(465 nm excitation)

















Mixing ratio of




Oxygen

Peak




raw materials
Bulk



existing ratio in

Intensity
Peak



(molar ratio)
density
Temperature
Time
Pressure
raw material
Eu raw
[relative
wavelength




















Eu
Ca
Al
Si
[g/cm3]
[° C.]
[hour]
[atm]
[% by mol]
material
value]
[nm]






















Example
0.008
0.992
1
1
0.35
1600
10
1.1
5
Eu2O3
128
652


101














Example
0.008
0.992
1
1
0.35
1600
10
1.1
5
EuF3
114
650


102














Example
0.008
0.992
1
1
0.35
1600
2
1.1
5
EuN
112
649


103









The following will explain the lighting equipment using a phosphor comprising the nitride of the invention. FIG. 14 shows a schematic structural drawing of a white LED as a lighting equipment. Using a blue LED 2 of 450 nm as a light-emitting element, the phosphor of Example 1 of the invention and a yellow phosphor of Ca-α-sialon:Eu having a composition of Ca0.75EU0.25Si8.625Al3.375O1.125N14.875 are dispersed in a resin layer to form a structure where the blue LED 2 is covered with the resulting resin layer. When electric current is passed through the electroconductive terminals, the LED 2 emits a light of 450 nm and the yellow phosphor and the red phosphor are excited with the light to emit yellow and red lights, whereby the light of LED and the yellow and red lights are mixed to function as a lighting equipment emitting a lamp-colored light.
A lighting equipment prepared by a combination design different from the above combination may be shown. First, using an ultraviolet LED of 380 nm as a light-emitting element, the phosphor of Example 1 of the invention, a blue phosphor (BaMgAl10O17:Eu), and a green phosphor (BaMgAl10O17:Eu,Mn) are dispersed in a resin layer to form a structure where the ultraviolet LED is covered with the resulting resin layer. When electric current is passed through the electroconductive terminals, the LED emits a light of 380 nm and the red phosphor, the green phosphor, and the blue phosphor are excited with the light to emit red, green, and blue lights, whereby these lights are mixed to function as a lighting equipment emitting a white light.
A lighting equipment prepared by a combination design different from the above combination may be shown. First, using a blue LED of 450 nm as a light-emitting element, the phosphor of Example 1 of the invention and a green phosphor (BaMgAl10O17:Eu,Mn) are dispersed in a resin layer to form a structure where the blue LED is covered with the resulting resin layer. When electric current is passed through the electroconductive terminals, the LED emits a light of 450 nm and the red phosphor and the green phosphor are excited with the light to emit red and green lights, whereby the blue light of LED and the green and red lights are mixed to function as a lighting equipment emitting a white light.
The following will explain a design example of an image display unit using the phosphor of the invention. FIG. 15 is a principle schematic drawing of a plasma display panel as an image display unit. The red phosphor of Example 1 of the invention, a green phosphor (Zn2SiO4:Mn), and a blue phosphor (BaMgAl10O17:Eu) are applied on the inner surface of cells 11, 12, and 13, respectively. When electric current is passed through electrodes 14, 15, 16, and 17, a vacuum ultraviolet ray is generated in the cells by Xe discharge and thereby the phosphors are excited to emit red, green, and blue visible lights. The lights are observed from the outside through the protective layer 20, the dielectric layer 19, and the glass substrate 22, whereby the unit functions as an image display.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
The present application is based on Japanese Patent Application No. 2003-394855 filed on Nov. 26, 2003, Japanese Patent Application No. 2004-41503 filed on Feb. 18, 2004, Japanese Patent Application No. 2004-154548 filed on May 25, 2004, and Japanese Patent Application No. 2004-159306 filed on May 28, 2004; and the contents are incorporated herein by reference.
INDUSTRIAL APPLICABILITY
The nitride phosphor of the invention exhibits emission at a longer wavelength as compared with conventional sialon and oxynitride phosphors and is excellent as a red phosphor. Furthermore, since luminance decrease of the phosphor is small when it is exposed to an excitation source, it is a nitride phosphor suitably used for VFD, FED, PDP, CRT, white LED, and the like. Hereafter, it is expected that the phosphor is widely utilized in material design in various display units and thus contributes development of industry.

## Claims

1. A phosphor comprising an inorganic compound represented by the composition formula:


MaAbDcEdXe 

wherein:
M is one or two or more elements selected from the group consisting of Mn, Ce, Pr, Nd, Sm, Eu, Tb, Dy, Ho, Er, Tm, and Yb;
A is one or two or more elements selected from the group consisting of divalent metal elements other than M Element;
D is one or two or more elements selected from the group consisting of tetravalent metal elements;
E is one or two or more elements selected from the group consisting of trivalent metal elements;
X is one or two or more elements selected from the group consisting of O, N, and F;


a+b=1;



0.00001≦a≦0.1;



0.5≦c≦1.8;



0.5≦d≦1.8;



0.8×(2/3+4/3×c+d)≦e; 



e≦1.2×(2/3+4/3×c+d).

2. The phosphor of claim 1, wherein the inorganic compound has the same crystal structure as CaAlSiN3 or a crystal structure such that:
positions of skeletal atoms in the inorganic compound are not sufficiently different from skeletal atoms in CaAlSiN3 that corresponding chemical bonds are cleaved; and
lengths of chemical bonds in the inorganic compound corresponding to Al—N and Si—N bonds in CaAlSiN3 differ from lengths of Al—N and Si—N bonds in CaAlSiN3 by +15%.

3. The phosphor of claim 1, wherein the inorganic compound comprises CaAlSiN3:Eu.

4. The phosphor according to claim 1, wherein:
A is one or two or more elements selected from the group consisting of Mg, Ca, Sr, and Ba;
D is one or two or more elements selected from the group consisting of Si, Ge, Sn, Ti, Zr, and Hf; and
E is one or two or more elements selected from the group consisting of B, Al, Ga, In, Sc, Y, La, Gd, and Lu.

5. The phosphor according to claim 1, wherein:
M comprises Eu;
A comprises Ca;
D comprises Si;
E comprises Al; and
X comprises N.

6. The phosphor according to claim 1, wherein the inorganic compound is a CaAlSiN3 crystal phase or a solid solution of a CaAlSiN3 crystal phase.

7. The phosphor according to claim 1, wherein:
M comprises Eu;
A comprises Ca;
D comprises Si;
E comprises Al; and
X comprises a mixture of N and O.

8. The phosphor according to claim 1, wherein A comprises Sr.

9. The phosphor according to claim 8, wherein numbers of atoms of Ca and Sr in the inorganic compound satisfy:


0.02≦(number of atoms of Ca)/{(number of atoms of Ca)+(number of atoms of Sr)}<1.

10. The phosphor according to claim 1, wherein X comprises N and O.

11. The phosphor according to claim 10, wherein numbers of atoms of O and N in the inorganic compound satisfy:


0.5≦(number of atoms of N)/{(number of atoms of N)+(number of atoms of 0)}≦1.

12. The phosphor according to claim 10, wherein the inorganic compound is represented by:


MaAbD1−xE1+xN3−xOx 

wherein:
a+b=1; and
0<x≦0.5.

13. The phosphor according to claim 1, wherein:
the inorganic compound is in the form of a powder;
the powder has an average particle size of 0.1 μm to 20 μm; and
the powder comprises single crystal particles or aggregates of single crystals.

14. The phosphor according to claim 1, wherein the inorganic compound comprises impurity elements of Fe, Co, and Ni in an amount of 50 ppm or less.

15. The phosphor according to claim 1, comprising the inorganic compound and a further crystal phase or amorphous phase;
wherein the inorganic compound is present in an amount of at least 20% by weight based on a total weight of the inorganic compound and the further crystal phase or amorphous phase.

16. The phosphor according to claim 15, wherein the further crystal phase or amorphous phase comprises an inorganic substance having electroconductivity.

17. The phosphor according to claim 16, wherein the inorganic substance having electroconductivity is a material comprising an oxide, oxynitride, or nitride comprising one or two or more elements selected from the group consisting of Zn, Al, Ga, In, and Sn.

18. The phosphor according to claim 15, wherein the further crystal phase or amorphous phase differs in composition from the inorganic compound.

19. The phosphor according to claim 1, wherein the phosphor emits a fluorescent light having a peak wavelength of from 570 nm to 700 nm, when irradiated with an excitation source.

20. The phosphor according to claim 19, wherein the excitation source is an ultraviolet ray or visible light having a wavelength of 100 nm to 600 nm.

21. The phosphor according to claim 19, wherein:
the inorganic compound is a CaAlSiN3 crystal phase;
Eu is dissolved in the crystal phase; and
the phosphor emits a fluorescent light having a peak wavelength of from 600 nm to 700 nm, when irradiated with light having a wavelength of from 100 nm to 600 nm.

22. The phosphor according to claim 19, wherein the excitation source is an electron beam or an X-ray.

23. The phosphor according to claim 19, wherein the phosphor emits fluorescent light having a color satisfying:


0.45≦x≦0.7

as a value of (x, y) on the CIE coordinates.