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Multilayer design of hybrid phosphor film for application in LEDs
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Crosslinked polydimethylsiloxane (PDMS) composite coatings containing luminescent micrometer-sized yellow Y3Al5O12:Ce3+ (YAG:Ce3+) particles were prepared by spraying for potential applications in solid-state lighting. Blue light was down converted by phosphor particles to produce white light, yet poor color properties of YAG:Ce3+ stemmed from a deficiency of red. When nitride-based red phosphor was simply blended into the system, the electrostatic interaction of negatively charged YAG:Ce3+ and positively charged red phosphor particles caused remarkable clustering and heterogeneity in particle dispersion. Consequently, the light is dominantly blue and shifted to cold white. In other case, phosphor particles were sprayed onto the diffused polycarbonate substrate in stacked layers. Coatings with >80% inorganic content by mass with a thickness of 60 μm were subjected to thermal crosslinking, which the presence of the phosphor particles obstructed, presumably due to the hindrance of large phosphor particles in the diffusion of PDMS precursors. The coating of YAG:Ce3+ first followed by red phosphor in stacked layers produced better light output and color properties than the coating obtained by spraying the mixture at once. Monte Carlo simulation validated the hypothesis.