Seung-Yeon
Kwak
a,
Na
Ree Kim
a,
Jae
Hong Kim
b and
Byeong-Soo
Bae
*a
aLaboratory of Optical Materials and Coating (LOMC), Department of Materials Science and Engineering, Korea Advanced Institute of Science and Technology (KAIST), Daejeon 305-701, Republic of Korea. E-mail: bsbae@kaist.ac.kr; Fax: +82 42 350 3310; Tel: +82 42 350 4119
bDepartment of Chemical Engineering, Yeungnam University, Gyeongsan 712-749, Republic of Korea. E-mail: jaehkim@ynu.ac.kr; Fax: +82 53 810 4631; Tel: +82 53 810 2521
First published on 19th October 2012
White light-emitting diodes (LEDs) using a wavelength converter composed of a red dye-bridged hybrid (DBH) mixed with a green silicate phosphor are fabricated. The red DBH is synthesized by chemically bonding epoxy functional oligosiloxane and red fluorescent dye for application in a red wavelength converter of white LEDs. To date, inorganic phosphors and quantum dots have been reported as red emitters. In this report, we suggest a dye based red wavelength converter for high color rendering white LEDs. The structural and optical properties of the DBH are evaluated. The fabricated white LEDs have a high color rendering index up to 90. They show facile color temperature tunability, a broad color gamut, and sufficient efficacy of 33.3 lm W−1 for applications in lighting technology. Also, both forward-bias current stability and long-term thermal stability are achieved for solid-state lighting applications.
Recently, quantum dots (QDs) have been explored as a potential fluorescent material on the basis of their color tunability, narrow emission, and high luminescence efficiency.12–14 It was reported that incorporating red CdSe QDs with a green inorganic phosphor increases the CRI of a white LED up to 90.1.15 It was also reported that silica-coated InP/ZnS QDs together with a green phosphor and YAG showed a CRI value as high as 86.16 However, QDs are hazardous and expensive due to their difficult synthesis method, and their long-term stability has not been verified.
Organic dyes are inexpensive and can be used as an alternate fluorescent material in LEDs. The broad absorption band of these dyes allows for high efficiency and it is easy to modify their molecular structure to generate red fluorescence. However, they have poor stability as they can be degraded by oxygen, moisture, heat, and external light. Recently, we reported on a dye-bridged hybrid (DBH), a one-body system of a dye and matrix consisting of a sol–gel derived nano-sized oligosiloxane employed to overcome the poor stability of the dye.17–19 In a DBH, dyes are chemically bridged to oligosiloxane, and thereby the dyes are seized and caged in the dense siloxane network, leading to more stable characteristics. Molecular stacking of the dye molecules is prevented by the covalently bridged structure, and the concentration stability is thus enhanced and the dye is homogeneously dispersed in the matrix. We demonstrated that the photoluminescence characteristics were not degraded under 120 °C heat during hundreds of hours. Also, the photoluminescence intensity of the DBH is less sensitive to temperature, and thus its initial characteristics are preserved upon elevated temperature, since the internal molecular rotation is restricted by the chemical structure.
In this study, a red fluorescent DBH is synthesized using an epoxy functional oligosiloxane and red fluorescent dye for a red wavelength converter of a white LED. Scheme 1 presents the schematic procedure to synthesize a dye-bridged oligosiloxane (DBO) resin by a sol–gel process and a DBH by curing a DBO resin. First, the red dye is covalently bridged with alkoxysilane, forming an epoxy functional oligosiloxane, via a sol–gel process. Finally, this DBO resin becomes a solid-state DBH through epoxy curing. We have fabricated white LEDs using the DBH and a green silicate phosphor mixture and the characteristics of white LEDs are investigated. Exhibiting a high color rendering index of up to 90 and stability under forward-bias current and thermal stress, these LEDs offer potential as a solid-state lighting source.
Scheme 1 Fabrication scheme of dye-bridged oligosiloxane (DBO) resin by a sol–gel process and dye-bridged hybrid (DBH) by curing of DBO. |
(1) |
We examined the MALDI-TOF MS of the DBO resin to analyze the molecular weight distribution of oligosiloxane, which falls in the range of 630–3000 m/z. The calculated molecular weight and experimental molecular weight of each peak are summarized in Table 1, where it is seen that each peak position of the practical molecular weight matches that of the calculated molecular weight. Through a comparison of the two peaks, we confirmed that the oligosiloxane of the DBO resin has a well-defined structure with oligomer size.
Calculated (m/z) | Practical (m/z) | |
---|---|---|
Trimer | 640–648 | 629–661 |
Tetramer | 840–850 | 827–851 |
Pentamer | 1038–1050 | 1013–1055 |
Hexamer | 1236–1250 | 1211–1255 |
Heptamer | 1434–1450 | 1404–1453 |
Octamer | 1632–1650 | 1600–1652 |
The DBH is cured through epoxy polymerization with an anhydride hardener under quaternary phosphonium salts.20 The cured DBH was examined by FT-IR and 13C NMR to determine if it is fully cured. If the DBH was not fully polymerized, DBH would be degraded during thermal aging due to the existence of unreacted organic species and would show unreliable performance. Fig. 2 presents FT-IR spectra analysis results of the DBO resin and the cured DBH. A broad absorption spectrum of siloxane stretching is observed between 1130 cm−1 and 1020 cm−1 in the FT-IR spectra. Vibration of the epoxy group appears at 883 cm−1 and a CC band of phenyl groups originating from diphenylsilanediol is observed at 1592 cm−1. As the thermal curing proceeds, the band of the epoxy group decreases but the amount of phenyl groups remains uniform in the matrix. Thus, the conversion degree of epoxy, which represents how much epoxy participates in the polymerization, can be calculated by comparing the area of epoxy groups and phenyl groups before and after thermal curing. The conversion degree of epoxy calculated using eqn (2) is 97%.
(2) |
Fig. 2 FT-IR spectra of before and after curing of DBO resin. |
13C NMR of the DBO resin and solid-state 13C NMR of DBH were measured to verify epoxy ring opening during the curing to form DBH. Fig. 3 shows 13C NMR analysis results of the DBO resin and DBH. Before curing, carbon beside the oxygen of cycloaliphatic epoxy (1a, 2a) is detected at 51–53 ppm in the 13C NMR spectra. For the solid-state 13C NMR, the carbon of cycloaliphatic epoxy at 51–53 ppm is chemically shifted to 60–80 ppm (1b, 2b), since the epoxy ring is opened during the polymerization. These results indicate that the DBO resin is cured, leading to the realization of the DBH.
Fig. 3 13C NMR and solid-state 13C NMR spectra of before and after curing of DBO resin. (Inset molecular structure represents ring opening of epoxy). |
The refractive index is an important factor for high efficiency white LEDs, because a high refractive index encapsulant allows light to be efficiently extracted from the LED. The refractive index of the DBH is measured by a prism coupler at a wavelength of 632.8 nm. The measured value is as high as 1.536 due to the presence of the phenyl group with high electronic polarizability.
The dye concentration and the quantity of silicate phosphor in the resin mixture are controlled to optimize the white color of the encapsulated LED. The concentration of the red dye in the DBO resin is controlled from 0.01 mmol L−1 to 2 mmol L−1. It shows yellow emission when 10 wt% of silicate phosphor is dispersed in the DBO resin and the dye concentration is between 0.02 mmol L−1 and 0.1 mmol L−1. The color coordinates (x, y) on CIE 1931 color space are (0.3905, 0.5443), (0.4547, 0.5033), and (0.5167, 0.4483) for dye concentration of 0.02 mmol L−1, 0.05 mmol L−1, and 0.1 mmol L−1, respectively. The tri-chromatic white LEDs show various white emissions depending on the dye concentration in the DBO resin. Characteristics of the DBH/silicate phosphor encapsulated white LEDs such as color coordinates, CRI, and color temperature depending on the dye concentration are listed in Table 2. Their color space coordinates and the electroluminescence (EL) spectra are presented in Fig. 4. The DBH/silicate phosphor mixture provides advantages in controlling color temperature and CRI by varying the dye concentration in the DBH. It is known that color temperature over 5000 K is cool white and less than 4000 K is warm white. Color temperature can be easily turned from cool white to warm white in the white LED for many lighting applications.
Fig. 4 (a) Commission Internationale de l'Eclairage (CIE) color coordinates of the DBH/silicate phosphor encapsulated white LEDs. The dashed triangle is the color gamut of sRGB color space and the solid triangle represents the color gamut of DBH/silicate phosphor encapsulated white LED. (b) EL spectra of various DBH/silicate phosphor encapsulated white LEDs. |
Point | Dye concentration (mmol L−1) | CIE x | CIE y | Ra | TC (K) | Luminous efficacy (lm W−1) |
---|---|---|---|---|---|---|
A | 0.02 | 0.2921 | 0.336 | 75 | 7637 | 43.4 |
B | 0.05 | 0.3341 | 0.3237 | 90 | 5410 | 33.3 |
C | 0.1 | 0.3917 | 0.2877 | 82 | 2689 | 23.1 |
DBH has main emission at 635 nm when its dye concentration is 0.05 mmol L−1. After red DBH is mixed with green silicate phosphor, a main red emission peak is seen around 610 nm. We consider that this is because of the energy transfer occurring from green silicate phosphor to red dye when their distance is near enough. In other words, the main emission around 610 nm is an overlapped state of green silicate and red DBH in which energy transfer occurs. Interestingly, if we fabricate a white LED with layer-by-layer structure (blue LED/green phosphor/0.05 mmol L−1 red DBH), the white LED has red emission around 635 nm, which is the emission of 0.05 mmol L−1 DBH. That is, it shows their own emissions if energy transfer does not occur by splitting red and green emitters.
When the dye concentration is 0.05 mmol L−1 (point B, Fig. 4), the DBH/silicate phosphor encapsulated white LED has ideal properties of a white point at (0.3341, 0.3237) and a very high CRI up to 90. The general CRI (Ra) is the average of eight components and is related to the color difference between the test colors and original test color samples.21 We fabricated a YAG:Ce phosphor encapsulated white LED using the same blue LED package and epoxy functional oligosiloxane to compare color rendering with DBH/silicate phosphor encapsulated white LED. The amount of YAG:Ce in the white LED was controlled to have similar color coordinates of DBH/silicate phosphor white LED at (0.33, 0.3461). The CRI values of the DBH/silicate phosphor encapsulated white LED and a YAG:Ce phosphor white LED depending on the eight color components were compared (Fig. 5). CRI of the YAG:Ce phosphor white LED which has a di-chromatic source of 73. As presented in Fig. 5, color rendering at 7.5R and 10P, which represent light greyish red and light reddish purple has increased by 26 and 29 points, respectively. These results indicate that the red emission of the DBH/silicate phosphor encapsulated white LED is stronger than that of the YAG:Ce phosphor based white LED. Also color rendering at 2.5G and 10BG which are related to green emission, are increased by 18 and 26 points due to the green silicate phosphor.
Fig. 5 Color rendering index comparison of YAG:Ce encapsulated white LED and DBH/silicate phosphor encapsulated white LED (point B). |
The measured luminous efficacy of the DBH/silicate phosphor encapsulated white LED is between 23.1 and 43.4 lm W−1 using blue LED package with luminous efficacy of 9.2 lm W−1 at 20 mA. It was reported that the luminous efficacy of tri-chromatic white LEDs lies between 17–35 lm W−1 and luminous efficacy of tri-chromatic (green α-sialon:Yb2+ and red Sr2Si5N8:Eu2+) white LEDs was between 17–23 lm W−1.11 Another study on a green SrSi2O2N2:Eu and red CaSiN2:Ce based white LED showed luminous efficacy of 30 lm W−1.22 A white LED using CdSe red quantum dots with a green Sr3SiO5:Ce3+, Li+ showed efficiency of 14.0 lm W−1.15 The luminous efficacy of a green and red CdSe–ZnSe based white LED was 7.2 lm W−1.23 Thus, the present DBH/silicate phosphor encapsulated white LED has sufficient luminous efficacy compared to other reported tri-chromatic white LEDs.
The operation current has been increased from 20 mA to 80 mA at an interval of 20 mA to ensure stability under forward-bias current (Fig. 6). The number of photons emitted from the blue LED increases as the forward-bias current increases. If the red dye and silicate phosphor are not capable of accepting photons, the fluorescence intensity will be saturated. As seen in Fig. 6, the EL spectra show that the fluorescent intensity of the DBH and silicate phosphor is not saturated at high bias current. When the DBH/silicate phosphor encapsulated white LED is operated at 20 mA, it has color coordinates of (0.3341, 0.3237) and Ra is 90. After the forward current is increased to 80 mA, the white LED shows a CRI of 89 and the color coordinate is changed to (0.3395, 0.3303) that the changing range is (0.0054, 0.0066). The color temperature is changed from 5410 K to 5158 K. In a study by Jang et al., the color coordinates of a Sr3SiO5:Ce3+, Li+ and CdSe quantum dot based white LED varied from (0.2904, 0.2900) to (0.2914, 0.3017) and the CRI was changed from 90.1 to 88.9 when the forward-bias current was increased from 20 mA to 70 mA.15 With an increase of current from 10 mA to 60 mA, the color coordinates of a Tb3Al5O12:Ce3+ (TAG:Ce) based white LED varied from (0.3449, 0.3478) to (0.3408, 0.3349). In addition, a YAG:Ce based white LED showed color coordinate variation of (0.2923, 0.3281) to (0.2903, 0.3171) under the same conditions.24 It was reported that the fluorescent intensity of a red phosphor composed of Ca1−xSrxS:Eu2+ was saturated at current over 30 mA and a phosphor based white LED showed a decrease of Ra (92 → 88) and large variation of color coordinates.9 We can thus conclude that the present wavelength converter composed of a DBH and silicate phosphor has low photo-saturation and similar or higher stability under forward-bias current compared to quantum dot and inorganic phosphor based converters.
Fig. 6 EL spectra and color coordinate shift of DBH/silicate phosphor encapsulated white LED under various forward-bias current. |
The DBH/silicate phosphor encapsulated white LED was thermally aged at 120 °C in an air atmosphere for 800 h to confirm its thermal stability. Fig. 7 shows EL spectra of the fabricated white LED before and after thermal aging. The EL spectrum of the white LED was largely maintained over 800 h. If they are expressed as color coordinates, the initial point was (0.3619, 0.3351) and it shifted to (0.3595, 0.3338) after 800 h aging. The change of color coordinates is at the third decimal place, which could be within a reasonable error range. Dye molecules are chemically bonded to the robust siloxane structure and internal molecular rotation is restricted, thereby preventing thermal decomposition. Furthermore, the silicate phosphor is protected by the dense siloxane network, which has low gas permeability25 from moisture, leading to more stable characteristics. These results indicate that the DBH/silicate phosphor encapsulated white LED can properly operate at elevated temperature.
Fig. 7 EL spectra and color coordinate shift of DBH/silicate phosphor encapsulated white LED before and after thermal aging at 120 °C for 800 h. |
This journal is © The Royal Society of Chemistry 2012 |