WO2012032838A1 - β型サイアロンの製造方法 - Google Patents
β型サイアロンの製造方法 Download PDFInfo
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- WO2012032838A1 WO2012032838A1 PCT/JP2011/065281 JP2011065281W WO2012032838A1 WO 2012032838 A1 WO2012032838 A1 WO 2012032838A1 JP 2011065281 W JP2011065281 W JP 2011065281W WO 2012032838 A1 WO2012032838 A1 WO 2012032838A1
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
- C09K11/08—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials
- C09K11/77—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials containing rare earth metals
- C09K11/7728—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials containing rare earth metals containing europium
- C09K11/77348—Silicon Aluminium Nitrides or Silicon Aluminium Oxynitrides
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
- C04B35/597—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon oxynitride, e.g. SIALONS
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
- C09K11/08—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K11/00—Luminescent, e.g. electroluminescent, chemiluminescent materials
- C09K11/08—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials
- C09K11/64—Luminescent, e.g. electroluminescent, chemiluminescent materials containing inorganic luminescent materials containing aluminium
Definitions
- the present invention relates to a method for producing ⁇ -sialon that can be used in a light-emitting device such as a white light-emitting diode using a blue light-emitting diode chip or an ultraviolet light-emitting diode chip.
- Patent Document 1 the ⁇ -sialon produced in the first heating step is subjected to acid treatment through the second heating step, thereby improving crystallinity and increasing the brightness.
- Patent Document 2 discloses that the fluorescence spectrum of ⁇ -sialon can be shortened or narrowed by reducing the amount of solid solution of oxygen in ⁇ -sialon.
- an object of the present invention is to provide a method for producing ⁇ -sialon capable of realizing high luminous efficiency even when the wavelength of the fluorescence spectrum of ⁇ -sialon is shortened or narrowed.
- the composition of the raw material powder, the average particle size, the optical characteristics, and the properties of the obtained ⁇ -sialon as a phosphor Based on the results of the analysis of the relationship between the raw material powder and the production of ⁇ -sialon with high emission efficiency, short wavelength and narrow band by controlling the physical properties of the raw powder to a specific range It is.
- the present invention has a firing step of firing raw material powder, and is a method for producing ⁇ -sialon represented by the general formula: Si 6-z Al z O z N 8-z : Eu, Al content 0.3 to 1.2% by mass, O content 0.15 to 1% by mass, O / Al molar ratio 0.9 to 1.3, Si content 58 to 60% by mass, N content The amount is 37 to 40% by mass, the N / Si molar ratio is 1.25 to 1.45, and the Eu content is 0.3 to 0.7% by mass.
- the raw material powder is heated to a temperature of 1850 to 2050 ° C. in a nitriding atmosphere.
- part or all of the raw material powder is ⁇ -sialon.
- the light absorptivity of the raw material powder with respect to the excitation wavelength of 455 nm is preferably 40% or more, and the particle size of the raw material powder is preferably 1 ⁇ m to 12 ⁇ m at D50 and 20 ⁇ m or less at D90.
- This annealing process is an annealing process in which heat treatment is performed in a temperature range of 1200 ° C. or higher and 1550 ° C. or lower in vacuum, or in an inert atmosphere mainly containing a gas other than nitrogen having a nitrogen partial pressure of 10 kPa or lower. It is preferable that it is one or both of the annealing process heat-processed by temperature.
- An acid treatment step can be provided after the firing step or after the annealing step.
- ⁇ -sialon is impregnated in an aqueous solution containing HF and HNO 3 at 65 ° C. or higher.
- the present invention is a ⁇ -type sialon represented by the general formula: Si 6-z Al z O z N 8-z : Eu and having a firing step of firing raw material powder (hereinafter simply referred to as “ ⁇ -type sialon”).
- a raw material powder having an Al content of 0.3 to 1.2% by mass, an O content of 0.15 to 1% by mass, an O / Al molar ratio of 0.9 to 1.3, and an Si content 58-60 mass%, N content 37-40 mass%, N / Si molar ratio 1.25-1.45 and Eu content 0.3-0.7 mass%. Is fired in a temperature range of 1850 to 2050 ° C.
- the produced ⁇ -type sialon has a CIExy chromaticity coordinate of 0.280 ⁇ x ⁇ 0.340 and 0.630 ⁇ y ⁇ 0.675. It is a manufacturing method of type sialon.
- the raw material powder of the present invention has an Al content of 0.3 to 1.2% by mass, an O content of 0.15 to 1% by mass, an O / Al molar ratio of 0.9 to 1.3, and an Si content.
- an amount of 58 to 60% by mass an N content of 37 to 40% by mass, an N / Si molar ratio of 1.25 to 1.45 and an Eu content of 0.3 to 0.7% by mass. The proportion is adjusted.
- the content of Al in the raw material powder is 0.3 to 1.2% by mass. If the content of Al in the raw material powder is small, the light emission efficiency of ⁇ -sialon tends to be reduced, and if it is large, the wavelength is not reduced and the band is not narrowed.
- the content of O in the raw material powder is 0.15 to 1% by mass.
- the oxygen content is low, grain growth during firing does not occur sufficiently, crystal defects increase, the emission efficiency of ⁇ -sialon decreases, and shortening of the wavelength and narrowing of the bandwidth cannot be sufficiently achieved.
- the oxygen content increases, phosphor particles having a large aspect ratio and a narrow minor axis are formed during grain growth during firing, resulting in a decrease in absorptance, and from the excitation light of Eu as the emission center to fluorescence.
- the conversion ability of the ⁇ -sialon decreases, and the luminous efficiency of ⁇ -sialon decreases.
- the O / Al molar ratio of the raw material powder is 0.9 to 1.30.
- the content of Si in the raw material powder is 58 to 60% by mass. If the Si content is low, the weight during the firing process tends to decrease and the yield tends to decrease. If the Si content is high, the transparency of the crystal is impaired, the internal quantum efficiency decreases, and the light emission efficiency decreases.
- the content of N in the raw material powder is 37 to 40% by mass.
- the N / Si molar ratio is 1.25 to 1.45. Even if the N / Si molar ratio is high or low, ⁇ -sialon close to the stoichiometric ratio cannot be formed, so that sufficient luminous efficiency cannot be obtained.
- the content of Eu in the raw material powder is 0.3 to 0.7% by weight. If the Eu content is low, the excitation light cannot be sufficiently converted to green light, and the light emission efficiency decreases. On the other hand, when the content of Eu is large, excess Eu atoms that cannot be dissolved are precipitated between the particles, and a part of the excitation light and fluorescence are absorbed to reduce the light emission efficiency.
- the raw material powder is fired in a temperature range of 1850 to 2050 ° C. in a nitriding atmosphere.
- the ⁇ -sialon obtained in the baking step exhibits fluorescence characteristics, and the fluorescence characteristics of CIExy chromaticity coordinates of 0.280 ⁇ x ⁇ 0.340 and 0.630 ⁇ y ⁇ 0.675 are obtained.
- the raw material powder is filled into a container such as a crucible having at least a surface part in contact with the raw material powder made of boron nitride, and fired in a temperature range of 1850 to 2050 ° C. in a nitrogen atmosphere.
- a container such as a crucible having at least a surface part in contact with the raw material powder made of boron nitride, and fired in a temperature range of 1850 to 2050 ° C. in a nitrogen atmosphere.
- grain growth occurs, resulting in grain coarsening and further improvement in crystallinity.
- Eu efficiently emits fluorescent light, so that the emission efficiency is improved, and ⁇ -sialon with a shorter wavelength and a narrower band is synthesized.
- the raw material powder may be ⁇ -sialon.
- the light absorption rate with respect to the excitation wavelength of 455 nm of the raw material powder is 40% or more.
- the ⁇ -sialon contained in the raw material powder is a powder of a metal or compound containing the elements constituting the ⁇ -sialon, and after adjusting the composition and crystallinity by a heat treatment step, the particle size is adjusted by a pulverization process, etc. What is necessary is just to produce by this method.
- the particle size of the raw material powder is preferably 1 ⁇ m or more and 12 ⁇ m or less at D50 and 20 ⁇ m or less at D90.
- D50 and D90 are 50% particle size and 90% particle size, respectively, in the volume-based integrated fraction. If the grain size of D50 is too small, grain growth occurs rapidly during firing and crystal defects increase, resulting in a decrease in the luminous efficiency of the obtained ⁇ -sialon. On the contrary, when the particle size of D50 is large, sufficient grain growth does not occur, and the luminous efficiency of the fired ⁇ -sialon is not improved. When the particle size of D90 is large, coarse particles that cannot be used as a product increase in the fired ⁇ -sialon, and the yield decreases.
- the raw material powder of the present invention Since the raw material powder of the present invention has a larger particle size than the powder used in the conventional production method, the abundance ratio of particles that do not participate in grain growth is increased in the firing process. Moreover, if the crystallinity of the raw material powder itself is poor, the crystallinity of ⁇ -sialon synthesized by firing also deteriorates, and the transparency and fluorescence characteristics of the crystal deteriorate. However, if the raw material is made of ⁇ -sialon powder, which is polycrystalline, rather than a single crystal powder such as metal or compound powder, the crystallinity of ⁇ -sialon obtained by firing is improved.
- ⁇ -sialon powder which is polycrystalline
- An annealing step may be provided after the firing step.
- heat treatment is performed in a temperature range of 1200 ° C. or higher and 1550 ° C. or lower in a vacuum, or in an inert atmosphere mainly containing a gas other than nitrogen gas having a nitrogen partial pressure of 10 kPa or lower. You may heat-process at temperature.
- the annealing process may be performed in two stages. Heat treatment in an inert atmosphere may be performed before and after the heat treatment step in vacuum.
- the acid treatment step is preferably a step of impregnating ⁇ -sialon into an aqueous solution containing HF and HNO 3 at 65 ° C. or higher.
- acid treatment is performed at a temperature of 65 ° C. or higher in an aqueous solution composed of HF and HNO 3 .
- the acid treatment removes impurities made of crystals such as amorphous and Si other than the ⁇ -type sialon crystal phase generated in the firing step and annealing step, and further improves the luminous efficiency.
- Example 1 In the method for producing ⁇ -sialon of Example 1 according to the present invention, a raw material powder containing ⁇ -sialon in the raw material powder and having a z value calculated from the amount of Al of 0.1 is calcined, and the general formula: A ⁇ -sialon represented by Si 6-z Al z O z N 8-z : Eu was produced.
- the raw material powder according to Example 1 has an Al content of 0.50 mass%, an O content of 0.91 mass%, an O / Al molar ratio of 1.15, an Si content of 59.1 mass%, N The content was adjusted to 38.8% by mass, the N / Si molar ratio was 1.32 and the Eu content was adjusted to 0.50% by mass.
- the raw material powder is filled in a boron nitride container (“N-1” grade manufactured by Denki Kagaku Kogyo Co., Ltd.) and fired at a temperature of 2000 ° C. for 10 hours in a 0.9 MPa pressurized nitriding atmosphere.
- ⁇ -sialons having 0.280 ⁇ x ⁇ 0.340 and 0.630 ⁇ y ⁇ 0.675 were synthesized.
- D50 of the raw material powder was 6.0 ⁇ m, and D90 was 16.6 ⁇ m.
- D50 and D90 were measured by a laser diffraction scattering method.
- This measurement was performed as follows. 50 mg of the raw material powder for phosphor synthesis of Example 1 was put in an ESR sample tube, and ESR measurement was performed at 25 ° C.
- an ESR measuring device JES-FE2XG type manufactured by JEOL Ltd. was used. The measurement conditions were as follows.
- Magnetic field sweep range 3200-3400gauss (320-340mT) Magnetic field modulation: 100kHz, 5gauss Irradiation microwave: frequency 9.25 GHz, output 10 mW Sweep time: 240 seconds Number of data points: 2056 points Standard sample: and the Mn 2+ was measured at the same time as the sample of Example 1 which was thermally diffused to MgO.
- the ESR spectrum is usually observed as a first-order differential curve because the unevenness of the absorption spectrum of electromagnetic waves is sensitively observed. Since the absorption intensity is proportional to the number of spins, the ESR spectrum was integrated twice, the differential curve was corrected to an integral curve, and quantified from the area ratio with the standard sample.
- the spin number of the standard sample is 1,1-diphenyl-2-picrylhydrazyl ((C 6 H 5 ) 2 NNC 6 H 2 (NO 2 ) 3 , hereinafter referred to as DPPH) whose spin number is known.
- ESR measurement was performed on 0.5 mL (3.0 ⁇ 10 15 spins) of a 1.0 ⁇ 10 ⁇ 5 mol / L benzene solution, and was determined from the peak area ratio of the standard sample and the DPPH solution.
- the sintered product obtained in the above baking process was loosely agglomerated and could be loosely loosened manually by wearing clean rubber gloves. After mild crushing, ⁇ -sialon sintered powder was produced through a sieve having an opening of 45 ⁇ m.
- the obtained powder did not shrink due to sintering, had almost the same properties as before heating, and passed through a sieve having an opening of 45 ⁇ m.
- a trace amount of Si was detected.
- This powder was treated at a temperature of 70 ° C. in a 1: 1 mixed acid of 50% hydrofluoric acid and 70% nitric acid. Then, it washed with water and dried and obtained the beta type sialon powder of Example 1. As a result of XRD measurement again, no diffraction peaks other than ⁇ -sialon were detected.
- Table 1 shows the conditions in the method for producing ⁇ -sialon according to Examples and Comparative Examples, and the evaluation results of ⁇ -sialon produced by the production method.
- the light absorptance for the excitation wavelength of 455 nm was 50.9%.
- the light absorptance was measured with an instantaneous multi-photometry system (manufactured by Otsuka Electronics Co., Ltd., MCPD-7000).
- the emission peak intensity of ⁇ -sialon produced by the production method of Example 1 was 196%.
- the fluorescence spectrum was measured using a spectrofluorometer (manufactured by Hitachi High-Technologies Corporation, F4500).
- the height of the peak wavelength of the fluorescence spectrum when 455 nm blue light was used as the excitation light was measured, and the peak wavelength measured from YAG: Ce: phosphor (P46-Y3, manufactured by Kasei Opto) measured under the same conditions.
- the relative value with respect to the height was determined as the emission peak intensity.
- a spectral xenon lamp light source was used as the excitation light.
- the CIE chromaticity x of the fluorescence spectrum was 0.336, and the CIE chromaticity y was 0.637.
- the fluorescence spectrum was determined by measuring the fluorescence spectrum of the total luminous flux using an instantaneous multi-photometry system (MCPD-7000, manufactured by Otsuka Electronics Co., Ltd.) and collecting the fluorescence for excitation at 455 nm using an integrating sphere (Non-patent Document 1). reference).
- the z value calculated from the Al content in the raw material powder is 0.1, and the Eu content, Al content, O content, Si content, and N content are each 0.00%. 56, 0.91, 0.52, 58.8, 39.1% by mass, the O / Al molar ratio was 0.96, and the N / Si molar ratio was 1.33.
- the particle size and crystallinity of the raw material powder were evaluated by the same method as in Example 1.
- the particle size of the raw material powder was 6.2 ⁇ m for D50 and 14.2 ⁇ m for D90.
- the light absorptivity of the raw material powder with respect to the excitation wavelength of 455 nm was 58.0%.
- the z value calculated from the Al amount in the raw material powder was 0.08, and as a result of measuring the Eu content, Al content, O content, Si content, N content, They were 0.55, 0.76, 0.47, 58.7, and 39.4 mass%, respectively, the O / Al molar ratio was 1.04, and the N / Si molar ratio was 1.35.
- the particle size and crystallinity of the raw material powder were evaluated by the same method as in Example 1.
- the particle size of the raw material powder was 6.0 ⁇ m for D50 and 15.1 ⁇ m for D90.
- the light absorptivity of the raw material powder with respect to the excitation wavelength of 455 nm was 48.7%.
- the z value calculated from the amount of Al in the raw material powder of the raw material powder of Example 4 is 0.06.
- Eu content, Al content, O content, Si content, and N content they were 0.41, 0.59, 0.43, 59.1, and 39.3 mass%, respectively.
- the / Al molar ratio was 1.23 and the N / Si molar ratio was 1.33.
- the particle size and crystallinity of the raw material powder were evaluated by the same method as in Example 1.
- D50 was 5.1 ⁇ m
- D90 was 16.3 ⁇ m.
- the light absorption rate of the raw material powder with respect to the excitation wavelength of 455 nm was 45.2%.
- Comparative Example 1 The raw material powder of Comparative Example 1 is ⁇ -type silicon nitride powder (Ube Industries, E10 grade, O content 1.17% by mass), aluminum nitride powder (Tokuyama, F grade, O content 0.84 mass) %), Aluminum oxide powder (manufactured by Daimei Chemical Co., Ltd., TM-DAR ", grade), and europium oxide powder (manufactured by Shin-Etsu Chemical Co., Ltd., RU grade).
- ⁇ -type silicon nitride powder Ube Industries, E10 grade, O content 1.17% by mass
- aluminum nitride powder Tokuyama, F grade, O content 0.84 mass
- Aluminum oxide powder manufactured by Daimei Chemical Co., Ltd., TM-DAR ", grade
- europium oxide powder manufactured by Shin-Etsu Chemical Co., Ltd., RU grade.
- the z value calculated from the amount of Al in the raw material powder is 0.25, and 95.50 mass% silicon nitride powder, 3.32 mass% aluminum nitride powder so that the europium oxide powder is 0.29 mol%, Compounding 0.39% by mass of aluminum oxide powder and 0.79% by mass of europium oxide powder, mixing these raw material powders so as to have a particle size different from that of Example 1, did.
- the ⁇ -sialon of Comparative Example 1 was produced under the same conditions as in Example 1 except for these conditions.
- the particle size and crystallinity of the raw material powder were evaluated.
- the particle size of the raw material powder was D50 of 0.65 ⁇ m and D90 of 2.0 ⁇ m.
- the light absorptance with respect to the excitation wavelength of 455 nm was 22.6%.
- Example 1 Evaluation as a phosphor was performed in the same manner as in Example 1.
- the ⁇ -sialon of Comparative Example 1 has high emission intensity, it has a high CIE chromaticity x value and a low CIE chromaticity y value because of the high content of Al and O in the raw material powder. Met. Therefore, the ⁇ type sialon of Comparative Example 1 could not achieve a shorter fluorescence wavelength or a narrower band than the ⁇ type sialon of Examples 1 to 4.
- Comparative Example 2 The raw material powder of Comparative Example 2 has a silicon nitride powder of 97.8% by mass and an aluminum nitride powder so that the z value calculated from the amount of Al in the raw material powder is 0.1 and the europium oxide powder is 0.29 mol%. 1.5% by mass and 0.77% by mass of europium oxide powder were blended. This was used as a raw material powder for phosphor synthesis so as to have a particle size different from that of Example 1. The ⁇ -sialon of Comparative Example 2 was prepared under the same conditions as in Example 1 except for these conditions.
- the particle size and crystallinity of the raw material powder of Comparative Example 2 were evaluated.
- the particle size of the raw material powder of Comparative Example 2 was D50 of 0.62 ⁇ m and D90 of 1.9 ⁇ m.
- the light absorptance with respect to the excitation wavelength of 455 nm was 23.5%.
- the ⁇ -sialon of Comparative Example 2 has a low Al content in the raw material powder, the value of chromaticity x is low and the value of chromaticity y is high, that is, the wavelength is shortened and the band is narrowed. It is necessary for the charge balance of the crystal that the molar ratio of Al and O in ⁇ -sialon is 1: 1. In order to reduce the wavelength and narrow the band, in Examples 1 to 4, the amount of O and the amount of Al are reduced to reduce the z value.
- the molar ratio of O to Al in the raw material powder is significantly larger than 1 due to the impurity oxygen of the silicon nitride powder and the aluminum nitride powder and the oxygen contained in the europium oxide.
- the luminous efficiency decreased.
- the average particle size of the raw material powder was small and the crystal defects were large, the emission peak intensity was extremely low.
- the ⁇ -sialons of Examples 1 to 4 all had high emission intensity.
- the light emission of the ⁇ -sialons of Examples 1 to 4 is 0.319 ⁇ x ⁇ 0.336 and 0.637 ⁇ y ⁇ 0.650 in CIExy chromaticity, and a shorter wavelength and a narrower band are achieved. I found out.
- the ⁇ -sialons of Examples 1 to 10 of the present invention can emit high-intensity green light using an ultraviolet LED or a blue LED emitting light having a wavelength of 350 to 500 nm as excitation light. For this reason, in addition to the phosphor of the experimental example described above, a white LED having good light emission characteristics can be realized by using another phosphor that emits light of another color.
- the phosphor using the ⁇ -sialon of the present invention is excited in a wide wavelength range from ultraviolet to blue light, and exhibits high emission efficiency, short wavelength and narrow band green emission. For this reason, the phosphor using the ⁇ -sialon of the present invention can be suitably used as a phosphor of a white LED using blue light or ultraviolet light as a light source, and a color reproduction range for a backlight of a liquid crystal display panel. Can be suitably used for a wide range of white LEDs and the like.
- the phosphor using the ⁇ -sialon of the present invention has little decrease in luminance at high temperature, and is excellent in heat resistance and moisture resistance. Therefore, when the phosphor of the present invention is applied to the lighting equipment and image display device fields described above, changes in luminance and emission color with respect to changes in the operating environment temperature are small, and excellent long-term stability characteristics are exhibited. it can.
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Abstract
Description
本発明は、一般式:Si6-zAlzOzN8-z:Euで表され、原料粉末を焼成する焼成工程を有するβ型サイアロン(以下、単に「β型サイアロン」と呼ぶ)の製造方法であって、原料粉末が、Al含有量0.3~1.2質量%、O含有量0.15~1質量%、O/Alモル比0.9~1.3、Si含有量58~60質量%、N含有量37~40質量%、N/Siモル比1.25~1.45及びEu含有量0.3~0.7質量%を有し、焼成工程において、原料粉末を窒化雰囲気中1850~2050℃の温度範囲で焼成し、製造されるβ型サイアロンが、CIExy色度座標で0.280≦x≦0.340、0.630≦y≦0.675を示すβ型サイアロンの製造方法である。
焼成工程では、原料粉末を、少なくともこの原料粉末と当接する表面部分が窒化ホウ素でなる坩堝等の容器内に充填し、窒素雰囲気中で1850~2050℃の温度範囲で焼成する。これにより、粒成長が生じて粒子の粗大化と、さらなる結晶性の改善が生じる。その結果、Euが効率的に蛍光発光を示すことから、発光効率が向上し、かつ、短波長化及び狭帯域化させたβ型サイアロンが合成される。
実施例1の蛍光体合成用の原料粉末50mgをESR用の試料管に入れ、25℃でESR測定を行った。測定には、日本電子株式会社製のESR測定装置(JES-FE2XG型)を使用した。測定条件は、以下の通りであった。
磁場掃引範囲:3200~3400gauss(320~340mT)
磁場変調:100kHz、5gauss
照射マイクロ波:周波数9.25GHz、出力10mW
掃引時間:240秒
データポイント数:2056ポイント
標準試料:MgOにMn2+を熱拡散させたものを実施例1の試料と同時に測定した。
円筒型窒化ホウ素製容器に上記の焼結粉末を充填し、大気圧のAr雰囲気中、1450℃で8時間の加熱処理を行った。得られた粉末は、焼結に伴う収縮がなく、加熱前とほとんど同じ性状であり、目開き45μmの篩を全て通過した。XRD測定の結果、微量のSiが検出された。この粉末を50%フッ化水素酸と70%硝酸の1:1混酸中、70℃の温度で処理した。その後、水洗及び乾燥して実施例1のβ型サイアロン粉末を得た。再びXRD測定を行った結果、β型サイアロン以外の回折ピークは検出されなかった。
次に、実施例1と同様の方法で蛍光体の評価を行った。実施例2のβ型サイアロンの発光ピーク強度は201%であり、CIE色度は、x=0.332、y=0.640であった。
次に、実施例1と同じ方法で、蛍光体の評価を行った。
実施例3のβ型サイアロンを用いた蛍光体の発光ピーク強度は195%であり、CIE色度は、x=0.327、y=0.645であった。
次に、実施例1と同じ方法で蛍光体としての評価を行った。実施例4のβ型サイアロンの発光ピーク強度は183%であり、CIE色度は、x=0.319、y=0.650であった。
(比較例1)
比較例1の原料粉末は、α型窒化ケイ素粉末(宇部興産社製、E10グレード、O含有量1.17質量%)、窒化アルミニウム粉末(トクヤマ社製、Fグレード、O含有量0.84質量%)、酸化アルミニウム粉末(大明化学社製、TM-DAR」、グレード)、酸化ユーロピウム粉末(信越化学工業社製、RUグレード)の混合粉を用いた。原料粉末中のAl量から計算したz値が0.25であり、酸化ユーロピウム粉末を0.29モル%となるように、窒化ケイ素粉末95.50質量%、窒化アルミニウム粉末3.32質量%、酸化アルミニウム粉末0.39質量%及び酸化ユーロピウム粉末0.79質量%を配合し、これらの原料粉末を混合し、実施例1とは異なる粒度になるようにしてβ型サイアロン合成用の原料粉末とした。これら以外の条件は、実施例1と同じ条件で比較例1のβ型サイアロンを作製した。
比較例1のβ型サイアロンの発光ピーク強度は206%であり、CIE色度は、x=0.356、y=0.623であった。これにより、比較例1のβ型サイアロンは、発光強度は高いものの、原料粉末のAlとOの含有量が高いことから、CIE色度xの値が大きく、CIE色度yの値が小さいものであった。従って、比較例1のβ型サイアロンは、実施例1~4のβ型サイアロンと比較して、蛍光波長の短波長化や狭帯域化が実現できなかった。
比較例2の原料粉末は、原料粉中のAl量から計算したz値が0.1、酸化ユーロピウム粉末が0.29モル%となるように、窒化ケイ素粉末97.8質量%、窒化アルミニウム粉末1.5質量%、酸化ユーロピウム粉末0.77質量%を配合した。これを実施例1とは異なる粒度となるようにして蛍光体合成用の原料粉末とした。これら以外の条件は、実施例1と同じ条件で、比較例2のβ型サイアロンを作製した。
Claims (7)
- 原料粉末を焼成する焼成工程を有する、一般式:Si6-zAlzOzN8-z:Euで表されるβ型サイアロンの製造方法であって、
前記原料粉末が、Al含有量0.3~1.2質量%、O含有量0.15~1質量%、O/Alモル比0.9~1.3、Si含有量58~60質量%、N含有量37~40質量%、N/Siモル比1.25~1.45、及びEu含有量0.3~0.7質量%を有し、
前記焼成工程が、前記原料粉末を窒化雰囲気中1850~2050℃の温度範囲で焼成する焼成工程であり、
製造されるβ型サイアロンが、CIExy色度座標で0.280≦x≦0.340、0.630≦y≦0.675を示すβ型サイアロンの製造方法。 - 前記原料粉末の一部又は全部がβ型サイアロンであり、該原料粉末の455nmの励起波長に対する光吸収率が40%以上である請求項1に記載のβ型サイアロンの製造方法。
- 前記原料粉末の粒度が、D50で1μm以上12μm以下、D90で20μm以下である請求項1又は2に記載のβ型サイアロンの製造方法。
- 前記原料粉末の電子スピン共鳴スペクトルの計測における25℃でのg=2.00±0.02の吸収に対応するスピン密度が、9.0×1017個/g以下である請求項1又は2に記載のβ型サイアロンの製造方法。
- 前記焼成工程後にアニール工程を有し、該アニール工程が、真空中1200℃以上1550℃以下の温度範囲で熱処理するアニール工程、又は、窒素分圧10kPa以下の窒素以外のガスを主成分とした不活性雰囲気中1300℃以上1600℃以下の温度範囲で熱処理するアニール工程の一方又は双方である請求項1又は2に記載のβ型サイアロンの製造方法。
- 前記焼成工程の後又は前記アニール工程の後に酸処理工程を設け、該酸処理工程において、前記β型サイアロンを65℃以上のHFとHNO3を含有させた水溶液に含浸させる請求項1又は2に記載のβ型サイアロンの製造方法。
- 前記原料粉末の電子スピン共鳴スペクトルの計測における25℃でのg=2.00±0.02の吸収に対応するスピン密度が、9.0×1017個/g以下である請求項3に記載のβ型サイアロンの製造方法。
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US13/577,401 US20120298919A1 (en) | 2010-09-09 | 2011-07-04 | Method of manufacturing beta-sialon |
CN201180027981.3A CN102933683B (zh) | 2010-09-09 | 2011-07-04 | β 型赛隆的制备方法 |
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