# Patent

## Title
Light emitting device with an improved CaAlSiN light converting material

## Abstract

A light emitting device with a light source to emit primary light and a light conversion layer to convert at least a part of the primary light into secondary light includes a CaAlSiN light converting material with a transmissivity of ≧10% to ≦80% for a light in the wavelength range from ≧580 to ≦1000 nm.

## Background
The present invention is directed to light emitting devices, especially to the field of LEDs.
So-called phosphor converted light emitting devices comprising an electroluminescent light source and a light converting element to absorb light emitted from the light source at least partially and to re-emit secondary light with longer wavelengths are known from prior art. In recent times, the scope of LEDs comprising a CaAlSiN light converting phosphor material has been investigated and in this regard it has been found that such a material can be used in LEDs. An example is e.g. described in the EP05101834.9 which is incorporated by reference.
However, although the phosphor material described in this document shows good optical characteristics, the demands for LEDs, especially LEDs for use in cars require in most applications higher effectivity and temperature-stability.
It is an object of the present invention to provide a light-emitting device which comprises a CaAlSiN light converting material with improved effectivity and temperature stability.
This object is solved by a light-emitting device with a light source to emit primary light and a light conversion layer to convert at least a part of the primary light into secondary light comprising a CaAlSiN light converting material with a transmissivity of ≧10% to ≦80% for a light in the wavelength range from ≧580 to ≦1000 nm. Accordingly, a light emitting device, especially a LED is provided, comprising a CaAlSiN light converting material with a transmissivity of ≧10% to ≦80% for light in the wavelength area from ≧580 to ≦1000 nm. The light source may be one or more light sources from the group inorganic LEDs, organic LEDs or laser diodes.
The term “CaAlSiN light converting material” comprises and/or includes especially the following materials:

(Ca1−x−y−zSrxBayMgz)1−nAl1−a+bBaSi1−bN3−bOb:Mn 

    
    
        with 0≦x,y,z≦1, 0≦a≦1, 0≦b<1, 0≦n≦1 and M being a metal, according to an embodiment of the present invention selected out of the group comprising Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu or mixtures thereof
    
    


as well as a mixture of these materials with additives which may be added during ceramic processing. These additives may be incorporated fully or in part into the final material, which then may also be a composite of several chemically different species (CaAlSiN crystallites embedded into a glassy matrix of slightly different composition) and particularly include such species known to the art as fluxes. Suitable fluxes include alkaline earth—or alkaline—metal oxides and fluorides, SiO2 and the like.
The term “transmissivity” in the sense of the present invention means especially that ≧10%, according to an embodiment of the present invention ≧20%, according to an embodiment of the present invention ≧30%, according to an embodiment of the present invention ≧40% and ≦80% of the incident light of a wavelength, which cannot be absorbed by the material, is transmitted through the sample for normal incidence in air. This wavelength is according to an embodiment of the present invention, in the range of ≧580 nm and ≦1000 nm.
When using such a CaAlSiN light converting material, the features of the light-emitting device may in most applications be greatly improved (as will for some applications be described later on).
According to an embodiment of the present invention, the CaAlSiN light converting material emits secondary light in the red visible light wavelength area with a maximum intensity at a wavelength of ≧590 nm to ≦700 nm. This allows building up a light emitting device with improved characteristics. According to an embodiment of the present invention, the CaAlSiN light converting material has an emission band in the red visible light wavelength area with a maximum of ≧600 nm to ≦680 nm, or according to an another embodiment of the present invention, an emission band with a maximum of ≧620 nm to ≦670 nm.
According to an embodiment of the present invention, the CaAlSiN light converting material emits secondary light with a wavelength distribution with a half-width of ≧50 nm to ≦150 nm. This results in a sharp emission, which allows to further improve the light emitting device. According to an embodiment of the present invention, the CaAlSiN light converting material emits secondary light with a wavelength distribution with a half-width of ≧60 nm to ≦110 nm.
According to an embodiment of the present invention, the CaAlSiN light converting material has ≧97% to ≦100% of the theoretical single crystal density. By doing so, the CaAlSiN light converting material shows greatly improved mechanical and optical characteristics compared to materials with a lesser density. According to an embodiment of the present invention, the CaAlSiN light converting material has ≧98% to ≦100% of the theoretical single crystal density, according to an embodiment of the present invention ≧99% to ≦100% of the theoretical single crystal.
According to an embodiment of the present invention, the CaAlSiN light converting material is a polycrystalline material.
The term “polycrystalline material” in the sense of the present invention means especially a material with a volume density larger than 90 percent of the main constituent, consisting of more than 80 percent of single crystal domains, with each domain being larger than 0.5 μm in diameter and having different crystallographic orientations. The single crystal domains may be connected by amorphous or glassy material or by additional crystalline constituents.
According to an embodiment of the present invention, the CaAlSiN converting material is a ceramic material.
The term “ceramic material” in the sense of the present invention means especially a crystalline or polycrystalline compact material or composite material with a controlled amount of pores or which is free of pores.
According to an embodiment of the present invention the thickness of the ceramic material D is 30 μm≦D≦5000 μm, according to an embodiment of the present invention 60 μm≦D≦2000 μm and according to an embodiment of the present invention 80 μm≦D≦1000 μm.
According to an embodiment of the present invention, the shift of the maximum and/or the half-width of the secondary light emission in the red visible light wavelength area of the CaAlSiN light converting material is ≦20 nm over the whole temperature range from ≧550° C. to ≦150° C. By doing so, the light emitting device will show a constant behaviour during performance e.g. when used in a car.
According to an embodiment of the present invention, the shift of the maximum and/or the half-width in the emission band in the red visible light wavelength area of the CaAlSiN light converting material is ≧0 nm to ≦20 nm over the whole temperature range from ≧0° C. to ≦200° C., and according to an embodiment of the present invention, from ≧−40° C. to ≦250° C.
According to an embodiment of the present invention, the shift of the maximum and/or the half-width in the secondary light emission in the red visible light wavelength area of the CaAlSiN light converting material is ≧5 nm to ≦18 nm over the whole temperature range from ≧50° C. to ≦150° C., According to an embodiment of the present invention, ≧0° C. to ≦200° C., and According to an embodiment of the present invention, from ≧−40° C. to ≦250° C. According to an embodiment of the present invention, the shift of the maximum and/or the half-width in the secondary light emission in the red visible light wavelength area of the CaAlSiN light converting material is ≧10 nm to ≦15 nm over the whole temperature range from ≧50° C. to ≦150° C., According to an embodiment of the present invention, ≧0° C. to ≦200° C., and According to an embodiment of the present invention, from ≧−40° C. to ≦250° C.
According to an embodiment of the present invention, the CaAlSiN light converting material is selected out of a material comprising (Ca1−x−y−zSrxBayMgz)1−nAl1−a+bBaSi1−bN3−bOb:Ren, with 0≦x,y,z≦1, 0≦a≦1, 0≦b<1, 0≦n≦1 and RE selected out of the group comprising Eu, Ce, or mixtures thereof.
According to an embodiment of the present invention, the CaAlSiN light converting material is selected out of a material comprising (Ca1−x−y−zSrxBayMgz)1−nAl1−a+bBaSi1−bN3−bOb:Mn, with 0≦x,y,z≦1, 0≦a≦1, 0≦b<1, 0.002≦n≦0.2 and M being a metal, according to an embodiment of the present invention selected out of the group comprising Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu or mixtures thereof.
According to an embodiment of the present invention, the CaAlSiN light converting material is selected out of a material comprising (Ca1−x−y−zSrxBayMgz)1−nAl1−a+bBaSi1−bN3−bOb:Mn, with 0≦x,y,z≦1, 0≦a≦1, 0≦b<1, 0.002≦n≦0.2 and RE selected out of the group comprising Eu, Ce, or mixtures thereof.
According to an embodiment of the present invention, the CaAlSiN light converting material is selected out of a material comprising ((Ca1−x−y−zSrxBayMgz)1−0.5*k*nREk+n)1−a(Al1−mBm)bSi2−bN3−oOo with 0≦x,y,z≦1, 0≦m≦1, 0.002≦n≦0.2, b<o+1, a=0.5(1−o+b), 0≦o≦1, k=2 or 3 and RE selected out of the group comprising Eu, Ce, or mixtures thereof.
According to an embodiment of the present invention, the CaAlSiN light converting material is selected out of a material comprising ((Ca1−x−y−zSrxBayMgz)1−0.5*k*nREk+n)1−a(Al1−mBm)bSi2−bN3−oOo with 0≦x,y,z≦1, 0≦m≦1, 0.002≦n≦0.2, b<o+1, a=0.5(1−o+b), RE selected out of the group comprising Eu, Ce, or mixtures thereof, with 0≦o≦0.15; according to another preferred embodiment 0≦o≦0.01, according to a third preferred embodiment 0≦o≦0.02.
According to an embodiment of the present invention, the CaAlSiN light converting material is selected out of a material comprising ((Ca1−x−y−zSrxBayMgz)1−0.5*k*nREk+n)1−a(Al1−mBm)bSi2−bN3−oOo with 0≦x,y,z≦1, 0≦m≦1, 0.002≦n≦0.2, b<o+1, a=0.5(1−o+b), RE selected out of the group comprising Eu, Ce, or mixtures thereof, with 0≦o≦0.15; according to another preferred embodiment 0.01≦o≦0.15, according to a third preferred embodiment 0.02≦o≦0.1.
According to an embodiment of the present invention, the glass phase ratio of the CaAlSiN light converting material is ≧2 vol % to ≦5 vol %, according to an embodiment of the present invention, ≧3 vol % to ≦4 vol %. It has been shown in practice that materials with such a glass phase ratio show the improved characteristics, which are advantageous and desired for the present invention. The term “vol %” denotes the volume fraction given in percentage.
The term “glass phase” in the sense of the present invention means especially non-crystalline grain boundary phases, which may be detected by scanning electron microscopy or transmission electron microscopy.
According to a preferred embodiment of the present invention, the surface roughness RMS (disruption of the planarity of a surface; measured as the geometric mean of the difference between highest and deepest surface features) of the surface(s) of the CaAlSiN light converting material is ≧0.001 μm and ≦100 μm. According to an embodiment of the present invention, the surface roughness of the surface(s) of the CaAlSiN light converting material is ≧0.01 μm and ≦10 μm, according to an embodiment of the present invention ≧0.01 μm and ≦5 μm, according to an embodiment of the present invention ≧0.15 μm and ≦5 μm. and according to an embodiment of the present invention ≧0.2 μm and ≦2 μm.
According to a preferred embodiment of the present invention, the specific surface area of the CaAlSiN light converting material structure is ≧10−7 m2/g and ≦1 m2/g.
The present invention furthermore relates to a method of producing a CaAlSiN light converting material for a light-emitting device according to the present invention comprising a sintering step.
The term “sintering step” in the sense of the present invention means especially densification of a precursor powder under the influence of heat, which may be combined with the application of uniaxial or isostatic pressure, without reaching the liquid state of the main constituents of the sintered material.
According to an embodiment of the present invention, the sintering step is performed at ambient pressure, preferably in reducing or inert atmosphere.
According to an embodiment of the present invention, method furthermore comprises the step of pressing the CaAlSiN precursor material to ≧50% to ≦70%, according to an embodiment of the present invention, ≧55% to ≦60% of its theoretical single crystal density before sintering. It has been shown in practice that this improves the sintering steps for most CaAlSiN light converting materials as described with the present invention.
According to an embodiment of the present invention, the method of producing CaAlSiN light converting material for a light-emitting device according to the present invention comprises the following steps:

    
    
        (a) Mixing the precursor materials for the CaAlSiN light converting material
        (b) optional firing of the precursor materials, preferably at a temperature of ≧1300° C. to ≦1800° C. to remove volatile materials (such as CO2 in case carbonates are used)
        (c) optional grinding and washing
        (d) a first pressing step, preferably a uniaxial pressing step at ≧10 kN using a suitable powder compacting tool with a mould in the desired shape (e.g. rod- or pellet-shape) and/or a cold isostatic pressing step preferably at ≧3000 bar to ≦3500 bar
        (e) a sintering step at ≧1500° C. to ≦2200° C. at ambient pressure
        (f) a hot pressing step, preferably a hot isostatic pressing step preferably at ≧1100 bar to ≦2500 bar and preferably at a temperature of ≧1500° C. to ≦2000° C. and/or a hot uniaxial pressing step preferably at ≧100 bar to ≦2500 bar and preferably at a temperature of ≧1500° C. to ≦2000° C.
        (g) optionally a post annealing step at >1000° C. to <1700° C. in inert atmosphere or air
    
    


According to an embodiment of the present invention, the light-emitting device comprises a light emitting diode (LED), according to an embodiment of the present invention a LED based on AlInGaN material as the electroluminescent material.
According to an embodiment of the present invention, the light-emitting device comprises a first light converting material, according to an embodiment of the present invention a ceramic first light converting material, and a second light converting material.
According to an embodiment of the present invention, this second light converting comprises a YAG:Ce material. These materials have proven themselves in practice to be suitable for many applications within the present invention.
According to an embodiment of the present invention, the light emitting device has a color temperature of ≧3000K to ≦5000K, according to an embodiment of the present invention 3500K to ≦4000K.
The present invention also includes a method of preparing a light-emitting device according to the present invention comprising the steps of:

    
    
        (a) Providing at least a LED comprising a CaAlSiN first light converting material and at least a second luminescent color converter as described above
        (b) measuring the color temperature of the light emitting device
        (c) adjusting the color temperature of the light emitting device

whereby the steps (b) and (c) may be repeated ad libitum.

    
    


This method allows for most applications to define the color temperature of the light emitting device as desired and for most applications also to adjust the color temperature of the light-emitting device even after production.
According to an embodiment of the present invention, step c) is performed by abrasion of either the CalAlSiN material and/or the second luminescence color converter material.
According to an embodiment of the present invention, step c) is performed by changing the ratio of the amount of CaAlSiN light converting material and the second light converting material.
According to an embodiment of the present invention, this is performed by using plates or stripes of the CaAlSiN light converting material and the second luminescent color converter material, which are arranged laterally on the light emitting area of the LED chip. The color adjustment is performed by changing the ratio of plates or stripes of the CaAlSiN light converting material towards the plates or stripes of the second light converting material.
According to an embodiment of the present invention, color adjustment is performed by using several prefabricated LED chips which comprise certain different ratios of the CaAlSiN light converting material and second luminescent color converter material or comprise only one of the two materials, so that the adjustment may be performed by changing the brightness of the different LED chips in the light emitting device, or the amount of LED chips of a certain type. The first option will result in a color tunable device.
Additionally the color temperature may be set by changing the doping level in either the CaAlSiN light converting material and the second luminescent color converter material or changing the host lattice of either the CaAlSiN light converting material and the second light converting material (e.g. by adding Ga, Gd or Lu in case of a YAG material and/or adding Sr, Ba, Mg or O in case of the CaAlSiN light converting material). These measures may be used alone or in combination with the methods stated above.
A light emitting device according to the present invention as well as a CaAlSiN light converting material as produced with the present method may be of use in a broad variety of systems and/or applications, amongst them one or more of the following:

    
    
        Office lighting systems
        household application systems
        shop lighting systems,
        home lighting systems,
        accent lighting systems,
        spot lighting systems,
        theater lighting systems,
        fiber-optics application systems,
        projection systems,
        self-lit display systems,
        pixelated display systems,
        segmented display systems,
        warning sign systems,
        medical lighting application systems,
        indicator sign systems, and
        decorative lighting systems
        portable systems
        automotive applications
        green house lighting systems
    
    


The aforementioned components, as well as the claimed components and the components to be used in accordance with the invention in the described embodiments, are not subject to any special exceptions with respect to their size, shape, material selection and technical concept such that the selection criteria known in the pertinent field can be applied without limitations.



Additional details, characteristics and advantages of the object of the invention are disclosed in the sub-claims, the FIGURE and the following description of the respective FIGURES and examples, which—in an exemplary fashion—show an embodiment of a CaAlSiN light converting material for use in a light emitting device according to the invention.
FIG. 1 shows an emission spectra of an LED comprising a CaAlSiN light converting material according to Example I of the present invention



EXAMPLE I
FIG. 1 refers to (Ca0.95Sr0.05)0.98AlSiN3:Eu0.02 (Example I) which was produced as follows:
(Ca0.95Sr0.05)0.98AlSiN3:Eu0.02 was synthesized from 6.894 g Ca3N2 (Alfa Aesar, Karlsruhe, Germany), 710 mg SrN2 (Cerac, Milwaukee, Wis., USA), 6.148 g AlN (Nanoamor, Los Alamos, N. Mex., USA), amorphous 7.364 g SiN (Alfa Aesar) and 627 mg EuF3 (Aldrich, Taufkirchen, Germany). The powders were mixed in a porcelain mortar, filled into Molybdenum crucibles and fired for 4 h at 1450° C. in forming gas atmosphere. The resulting red powder was washed with acetic acid, water and 2-propanol to remove by-products and finer particles.
The obtained powder was compressed into pellets, cold isostatically pressed at 3200 bar and sintered at 1700° C. in forming gas atmosphere for 4 h. The resulting pellets displayed a closed porosity and were subsequently hot isostatically pressed at 2000 bar and 1700° C. to obtain dense ceramics with >98% of the theoretical density.
The thus produced (Ca0.95Sr0.05)0.98AlSiN3:Eu0.02 was incorporated into a light emitting device in form of a luminescence converting layer (638 nm peak wavelength, 200 μm (Ca0.93Sr0.05Eu0.02)AlSiN3 plate) using AlInGaN as an electroluminescent material having a wavelength of 450 nm.
FIG. 1 shows an emission spectra of this LED. The Color point is: x=0.615, y=0.384
The particular combinations of elements and features in the above detailed embodiments are exemplary only; the interchanging and substitution of these teachings with other teachings in this and the patents/applications incorporated by reference are also expressly contemplated. As those skilled in the art will recognize, variations, modifications, and other implementations of what is described herein can occur to those of ordinary skill in the art without departing from the spirit and the scope of the invention as claimed. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention's scope is defined in the following claims and the equivalents thereto. Furthermore, reference signs used in the description and claims do not limit the scope of the invention as claimed.

## Claims

1. A light emitting device comprising:
a light source to emit primary light; and
a light conversion layer to convert at least a part of the primary light into secondary light comprising a CaAlSiN light converting material with a transmissivity of ≧10% to ≦80% for a light in the wavelength range from ≧580 to ≦1000 nm, wherein the CaAlSiN light converting material is selected out of a material comprising (Ca1−x−y−zSrxBayMgz)1−nAl1−a+bBaSi1-bN3−bOb:Mn with 0<x,y,z≦1, 0<a≦1, 0<b<1, 0.002≦n≦0.2, M being a metal comprising at least one of Gd and Lu.

2. The light emitting device of claim 1, whereby the CaAlSiN light converting material emits secondary light in the red visible light wavelength range with a maximum intensity at a wavelength of ≧590 nm to ≦700 nm.

3. The light emitting device of claim 1, whereby the CaAlSiN light converting material emits secondary light with a wavelength distribution with a half-width of ≧50 nm to ≦150 nm.

4. The light emitting device of claim 1 whereby the CaAlSiN light converting material has a density of ≧97% to ≦100% of the theoretical single crystal density.

5. The light emitting device of claim 1 whereby the shift of the maximum and/or the half-width in the secondary light emission in the red visible light wavelength range of the CaAlSiN light converting material is 20 nm over the whole temperature range from ≧50° C. to ≦50° C.

6. The light emitting device of claim 1 whereby the glass phase ratio of the CaAlSiN light converting material is ≧2 vol % to ≦5 vol %.

7. A method of producing a CaAlSiN light converting material for a light emitting device comprising the acts of:
mixing powders of precursor material; and
heating the mixed powders to obtain a resulting powder comprising the CaAlSiN light converting material, wherein the CaAlSiN light converting material is selected out of a material comprising (Ca1−x−y−zSrxBayMgz)1−nAl1−a+bBaSi1−bN3−bOb:Mn with 0<x,y,z≦1, 0<a≦1, 0<b<1, 0.002≦n≦0.2, M being a metal comprising at least one of Gd and Lu.

8. The method of claim 7, further comprising the act of compressing the resulting powder into pellets by pressing at 3200 bar and sintering at 1700° C.

9. The method of claim 7, further comprising the act of, subsequent to the compressing act, further compressing the pellets by pressing at 2000 bar and sintering at 1700° C.

10. The method of claim 7, further comprising the act of compressing the resulting powder into pellets.