Manufacturing Process for Novel Solid State Lighting Phosphors

79586S Solid state lighting (SSL) is rapidly gaining momentum as a highly energy efficient replacement technology for traditional lamps. However, current devices made with solid state light-emitting diodes (LEDs) still suffer from low efficiencies, partly due to an optical mismatch between the LED and phosphor materials. Recently, a new class of phosphors were optically designed to maximize LED light outcoupling by carefully controlling their optical properties (refractive index, scattering, absorption, luminescence efficiency, etc.). This project will develop technology for the large-scale production of these new phosphor materials. Phase I will demonstrate the feasibility of a low-cost, continuous line production of the phosphor materials instead of the current batch process. A pilot production line will be constructed to demonstrate production volumes exceeding 75kg/month. Phase II will establish a production process for these materials at the levels that will be demanded by the future SSL market. Commercial Applications and Other Benefits as described by the awardee: The materials should find use in all LED systems, with applications in lighting in portable electronics, automobiles, and traffic signaling. The availability of efficient low-cost phosphor-converted LEDs, such as white light LEDs should open up a wide range of applications in general lighting where the cost/lumen is critical, thereby increasing the existing market penetration of LED lamps.