Glass member

Abstract

The present invention relates to a glass member in which an inorganic phosphor is dispersed in a glass matrix, in which the glass member includes an SiO.sub.2—B.sub.2O.sub.3 based glass as the glass matrix, and the SiO.sub.2—B.sub.2O.sub.3 based glass includes SiO.sub.2 as a main component thereof, and includes, based on a total amount of the SiO.sub.2—B.sub.2O.sub.3 based glass: Al.sub.2O.sub.3 in an amount of 4 to 10 wt %; and MgO and ZnO in a total amount of 0.1 to 0.7 wt %.

Claims

1. A glass member for wavelength conversion in which an inorganic phosphor is dispersed in a glass matrix, wherein: the glass matrix comprises a SiO.sub.2—B.sub.2O.sub.3 based glass as the glass matrix, and the SiO.sub.2—B.sub.2O.sub.3 based glass comprises, based on a total amount of the SiO.sub.2—B.sub.2O.sub.3 based glass: SiO.sub.2 in an amount of 60 to 70 wt %; B.sub.2O.sub.3 in an amount of 15 to 25 wt %; Al.sub.2O.sub.3 in an amount of 4 to 10 wt %; MgO and ZnO in a total amount of 0.1 to 0.7 wt %; and other metals or metal oxides in a total amount of 0.01 to 5 wt %; and the inorganic phosphor is contained in an amount of 25 vol % or more and 35 vol % or less based on a total volume of the glass member and comprises one or more of a phosphor of a garnet-based compound, a phosphor of nitride, or a phosphor of oxynitride, which are larger in refractive index than the SiO.sub.2—B.sub.2O.sub.3 based glass.

2. The glass member for wavelength conversion according to claim 1, wherein a cristobalite ratio in a glass region of the glass member is 1% or less.

3. The glass member for wavelength conversion according to claim 1, wherein a shape of the SiO.sub.2—B.sub.2O.sub.3 based glass which has not been subjected to a high temperature heat treatment yet during production of the glass member for wavelength conversion is powdery, and a maximum particle size (Dmax) thereof is 150 μm or less and an average particle size (D50) thereof is 0.1 μm or more, based on a laser diffraction method.

4. The glass member for wavelength conversion according to claim 2, wherein a content of the glass region is 60 to 80 wt % in the glass member.

5. The glass member for wavelength conversion according to claim 1, wherein the phosphor is a phosphor of nitride or a phosphor of oxynitride.

6. The glass member for wavelength conversion according to claim 1, wherein the nitride is CaAlSiN.sub.3.

7. The glass member for wavelength conversion according to claim 1, wherein the oxynitride is α-sialon or β-sialon.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) A glass member according to the present invention will be described below in detail.

(2) In the glass member according to the present invention, an inorganic phosphor is dispersed in a glass matrix. The glass member includes an SiO.sub.2—B.sub.2O.sub.3 based glass as the glass matrix. The SiO.sub.2—B.sub.2O.sub.3 based glass includes SiO.sub.2 as a main component thereof, and includes Al.sub.2O.sub.3 in an amount of 4 to 10 wt %, and MgO and ZnO in a total amount of 0.1 to 0.7 wt %. Here, the total amount of the SiO.sub.2—B.sub.2O.sub.3 based glass, namely the total amount of SiO.sub.2, B.sub.2O.sub.3, Al.sub.2O.sub.3, MgO, ZnO and the remainder is taken as 100 wt %.

(3) That is, the glass member includes at least SiO.sub.2, B.sub.2O.sub.3, Al.sub.2O.sub.3, and ZnO and/or MgO.

(4) SiO.sub.2 which is a main component of the SiO.sub.2—B.sub.2O.sub.3 based glass is a component forming a glass network. The content of SiO.sub.2 is specifically 60 to 70 wt %, and more preferably 62 to 65 wt % based on the total amount of the SiO.sub.2—B.sub.2O.sub.3 based glass. When the content of SiO.sub.2 is too small, crystallization of a glass part tends to proceed, and scattering of light in the glass member increases as the crystallization proceeds. That is, the optical path length of light propagated in the glass member is elongated so that emission light intensity tends to decrease due to a large optical loss. On the other hand, when the content of SiO.sub.2 is too large, meltability of the glass deteriorates so that the glass must be melted at a higher temperature to manufacture the glass member. Thus, due to deterioration of the inorganic phosphor caused by the high temperature heat treatment, the wavelength conversion efficiency tends to be lowered.

(5) B.sub.2O.sub.3 is a component which can decrease the melting temperature of the glass to thereby extremely improve the meltability thereof. The content of B.sub.2O.sub.3 is preferably 15 to 25 wt % based on the total amount of the SiO.sub.2—B.sub.2O.sub.3 based glass. When the content of B.sub.2O.sub.3 is less than 15 wt %, the effect of improving the meltability of the glass is so insufficient that the glass must be melted at a high temperature to manufacture the glass member. Thus, due to deterioration of the inorganic phosphor caused by the high temperature heat treatment, the wavelength conversion efficiency tends to be lowered. On the other hand, when the content of B.sub.2O.sub.3 exceeds 25 wt %, waterproofness or the like in the glass part of the glass member deteriorates. Thus, the durability as the glass member may deteriorate.

(6) Al.sub.2O.sub.3 is a component which can suppress the glass from being formed as cristobalite, and also improve the durability and the mechanical strength thereof. The content of Al.sub.2O.sub.3 is 4 to 10 wt %, and preferably 7 to 9 wt % based on the total amount of the SiO.sub.2—B.sub.2O.sub.3 based glass. When the content of Al.sub.2O.sub.3 is less than 4 wt %, the effect of suppressing the glass from being formed as cristobalite cannot be obtained sufficiently. Thus, a glass region in the glass member tends to be formed as cristobalite, so that scattering of light in the glass member tends to increase. That is, since the formation of the cristobalite is proceeded, many crystal nuclei grow to form aggregates of crystal grains and the optical path length are elongated. Thus, due to increase in optical loss, the emission light intensity tends to be lowered. On the other hand, when the content of Al.sub.2O.sub.3 exceeds 10 wt %, the waterproofness in the glass part of the glass member deteriorates. Thus, the durability as the glass member tends to deteriorate.

(7) MgO and ZnO are components which can decrease the melting temperature of the glass to thereby improve the meltability thereof. MgO and ZnO also serve as components which can decrease the softening point of the glass. The total content of MgO and ZnO is 0.1 to 0.7 wt %, and preferably 0.4 to 0.6 wt % based on the total amount of the SiO.sub.2—B.sub.2O.sub.3 based glass. When the total content of MgO and ZnO is less than 0.1 wt %, the effect of improving the meltability of the glass is so insufficient that the glass must be melted at a high temperature to manufacture the glass member. Thus, due to deterioration of the inorganic phosphor caused by the high temperature heat treatment, the wavelength conversion efficiency tends to be lowered. On the other hand, when the total content of MgO and ZnO exceeds 0.7 wt %, waterproofness or the like in the glass part deteriorates. Thus, the durability as the glass member tends to deteriorate.

(8) The inorganic phosphor is a general inorganic phosphor such as a phosphor of a garnet-based compound (such as YAG:Ce), a phosphor of nitride (such as CaAlSiN.sub.3), a phosphor of oxynitride (such as α-sialon (SiAlON) or β-sialon), etc.

(9) Such an inorganic phosphor is larger in refractive index than the glass. For example, in the glass member for wavelength conversion, assume that an inorganic phosphor having a large refractive index and a glass having a small refractive index are used in combination. In this case, excitation light is scattered in the interface between the inorganic phosphor and the glass matrix. When there is a large difference in refractive index between the both, the irradiation efficiency of the excitation light on the inorganic phosphor is enhanced to improve the wavelength conversion efficiency. However, when the difference in refractive index between the both is too large, the excitation light is scattered excessively to cause a scattering loss. Thus, the wavelength conversion efficiency is lowered.

(10) The content of the inorganic phosphor in the glass member is preferably 10 vol % or more and 40 vol % or less, and more preferably 14 vol % or more and 26 vol % or less, based on the total volume of the glass member. When the content of the inorganic phosphor is 10 vol % or more and 40 vol % or less, the quantity of light with a wavelength which can be transmitted through the glass member increases, while the quantity of light scattered or reflected by the inorganic phosphor decreases. Thus, the emission light intensity increases. When the content of the inorganic phosphor is less than 10 vol %, it may be difficult to obtain desired emission light intensity. On the other hand, when the content of the inorganic phosphor exceeds 40 vol %, the inorganic phosphor is less apt to be dispersed in the glass matrix. In addition, due to increase in porosity, the inorganic phosphor is hardly irradiated with the excitation light efficiently. In addition, the mechanical strength of the glass member tends to be lowered.

(11) In the glass member, the inorganic phosphor is dispersed in the glass matrix. The shape of the glass which has not been subjected to the high temperature heat treatment yet is preferably powdery because the glass is to be uniformly mixed with the powdery inorganic phosphor and subjected to the high temperature heat treatment. When the glass is powdery, it is preferable that a maximum particle size (Dmax) thereof is 150 μm or less and an average particle size (D50) thereof is 0.1 μm or more, based on a laser diffraction method. When the maximum particle size (Dmax) exceeds 150 μm, excitation light is hardly scattered in a wavelength conversion member obtained therefrom. Thus, the light emission efficiency tends to be lowered. On the other hand, when the average particle size (D50) is less than 0.1 μm, excitation light is excessively scattered in the glass member. Thus, the light emission efficiency tends to be lowered. It is more preferable that the maximum particle size (Dmax) is 30 μm or less and the average particle size (D50) is 0.5 μm or more and 10 μm or less. In addition, the softening point of the glass is preferably 400 to 850° C., and more preferably 500 to 810° C. When the softening point is less than 400° C., the mechanical strength and the durability of the glass member tend to be lowered. On the other hand, when the softening point exceeds 850° C., the heat treatment temperature of the wavelength conversion material becomes so high that the inorganic phosphor tends to deteriorate during the heat treatment.

(12) The SiO.sub.2—B.sub.2O.sub.3 based glass according to the present invention may contain a slight amount of other metals or metal oxides as long as they do not impair the effect of the present invention, in addition to the above-described components of SiO.sub.2, B.sub.2O.sub.3, Al.sub.2O.sub.3, MgO and ZnO. For example, components such as Li.sub.2O, Na.sub.2O and K.sub.2O may be contained. These components are components which decrease the melting point of the glass to thereby improve the meltability. However, these components decrease the softening point of the glass. Therefore, in order to maintain the durability, the total content of these components is set at about 0.01 to 5 wt % based on the total amount of the SiO.sub.2—B.sub.2O.sub.3 based glass.

(13) The cristobalite ratio in a glass phase (the glass region) of the glass member is preferably 1% or less. When the cristobalite ratio is 1% or less, light scattering in the glass member hardly increases. Thus, the optical loss does not increase, which leads to improvement of the emission light intensity, that is, the light emission efficiency. The content of such a glass phase is preferably 60 to 80 wt % in the glass member. Also, the porosity of the glass member is preferably 0.1% or less.

(14) The glass member according to the present invention is manufactured by baking a molded body including a mixture of the glass and the inorganic phosphor. The baking temperature is within a range of the softening point of the glass ±150° C. When the baking temperature is too low, the glass cannot flow. Thus, a dense sintered body is hardly obtained. On the other hand, when the baking temperature is too high, the inorganic phosphor may react in the glass to lower the emission light intensity, or a component contained in the inorganic phosphor may be dispersed into the glass so as to color the glass to thereby lower the emission light intensity. Further, deformation of the shape, segregation of the composition, etc. may occur.

(15) Baking is carried out under the atmosphere. In this manner, the quantity of bubbles remaining in the glass member can be reduced. As a result, scattering factors in the glass member can be reduced so that the light emission efficiency can be improved.

(16) The glass member according to the present invention is, for example, suitably used as a wavelength conversion member for a general lighting such as a white LED, a projector light source, a headlamp light source of a car, etc. In addition, the shape of the glass member is not particularly limited. For example, the glass member may be used as a member itself having a specific shape such as a sheet-like shape, a columnar shape, a hemispherical shape, a hemispherical dome-like shape, etc., or may be a sintered body formed like a film on a surface of a substrate such as a glass substrate or a ceramic substrate.

EXAMPLES

(17) The present invention will be described specifically based on Examples. The present invention is not limited by the following Examples.

Examples 1 to 14 and Comparative Examples 1 to 4

(18) Glass powder and inorganic phosphor powder as shown in Table I and binder were mixed, and then molded. Thus, a molded body 20 mm square and 0.25 mm thick was produced. Next, each molded body thus-produced was heated and melted in the atmosphere at 800° C. for 30 minutes to obtain a glass member in which inorganic phosphor was dispersed. Light emission efficiency of the obtained glass member was measured. The glass member to be subjected to this test was processed into a sample 1 mm square, and then fixed onto a blue LED element (light emission area: 1 mm square, emission light wavelength: 460 nm) by silicone resin.

(19) In an integrating sphere, blue light was irradiated on the inorganic phosphor, and a fluorescence spectrum was measured by a spectrometer. Absorbed energy and fluorescence energy were obtained from the obtained fluorescence spectrum. The ratio between the both was regarded as light emission efficiency.

(20) Next, the glass member was left as it was for 1,000 hours under the conditions of a temperature of 85° C. and a humidity of 85%. After that, the light emission efficiency was measured in the same manner as described above. When reduction in light emission efficiency was 2% or less, durability was regarded as good (A). When reduction in light emission efficiency exceeded 2%, durability was regarded as not good (B).

(21) The cristobalite ratio was measured by a 0-20 method performed by a powder X-ray diffractometry, and calculated based on a ratio of a peak area of crystalline components to a peak area (peak area of crystalline components+halo pattern area of amorphous components) appearing near 22°. When the cristobalite ratio was within 1%, it was regarded as good (A). When the cristobalite ratio exceeded 1%, it was regarded as not good (B).

(22) TABLE-US-00001 TABLE 1 Inorganic phosphor Light emission Cristobalite SiO.sub.2.sup.1) B.sub.2O.sub.3.sup.1) Al.sub.2O.sub.3.sup.1) MgO + ZnO.sup.1) Remainder.sup.1) content.sup.2) efficiency Durability ratio Comp. Ex. 1 65 20 3 0.5 11.5 25 90% A B Ex. 1 65 20 4 0.5 10.5 25 95% A A Ex. 2 65 20 6.5 0.5 8 25 95% A A Ex. 3 65 20 8.5 0.5 6 25 95% A A Ex. 4 65 20 10 0.5 4.5 25 95% A A Comp. Ex. 2 65 20 11 0.5 3.5 25 95% B A Comp. Ex. 3 65 20 6.5 0 8.5 25 91% A A Ex. 5 65 20 6.5 0.1 8.4 25 95% A A Ex. 6 65 20 6.5 0.7 7.8 25 95% A A Comp. Ex. 4 65 20 6.5 0.8 7.7 25 95% B A Ex. 7 65 20 6.5 0.5 8 9 92% A A Ex. 8 65 20 6.5 0.5 8 10 93% A A Ex. 9 65 20 6.5 0.5 8 15 93% A A Ex. 10 65 20 6.5 0.5 8 20 94% A A Ex. 11 65 20 6.5 0.5 8 30 96% A A Ex. 12 65 20 6.5 0.5 8 35 96% A A Ex. 13 65 20 6.5 0.5 8 40 93% A A Ex. 14 65 20 6.5 0.5 8 41 92% A A .sup.1)Unit of each value is wt %. .sup.2)Unit of each value is wt %. Each value shows the content (vol %) of inorganic phosphor to the total 100 vol % of glass matrix (SiO.sub.2, B.sub.2O.sub.3, Al.sub.2O.sub.3, MgO + ZnO and the remainder) and the inorganic phosphor. .sup.3)Each value shows the content of the remainder which is the total content (wt %) of BaO, CaO, Fe.sub.2O.sub.3, K.sub.2O, Li.sub.2O, Na.sub.2O, SnO, SrO and TiO.sub.2.

(23) In Comparative Example 1 where the content of Al.sub.2O.sub.3 was small, the cristobalite ratio exceeded 1%. It is considered that the reason therefor is that the formation of cristobalite proceeded inside the glass.

(24) In Comparative Example 3, the light emission efficiency was 91%, and the emission light intensity was lowered.

(25) On the other hand, in Comparative Example 2 where the content of Al.sub.2O.sub.3 was large and Comparative Example 4 where the total content of MgO and ZnO was large, the durability was lowered.

(26) The present application is based on Japanese patent application No. 2018-037782 filed on Mar. 2, 2018 and Japanese patent application No. 2019-024506 filed on Feb. 14, 2019, and the contents of which are incorporated herein by reference.