Roll-to-roll Manufacturing of RGB Phosphor Sheets for Solid State Lighting and Large Area Flexible Displays

摘要

We report on a novel low-cost approach for producing large format flexible RGB phosphor sheets with applications in both lighting and displays. The process can utilize any conventional down-conversion/up-conversion phosphor or non-phosphor optical powder materials regardless of particle size, shape, and composition. Both monochrome and patterned phosphor sheets can be produced in widths larger than 50 inch and lengths over 50 meters by roll-to-roll. Substrate thickness can vary from 50 microns (2 mils) to over 500 microns (20 mils) with monolayer control over phosphor coating thickness and better than 5% color uniformity. This technology is currently being used to produce high performance remote phosphor sheets for phosphor-converted white LEDs with ultra-high color rendering index (CRI>96) and correlated color temperature (CCT) from 2700K to over 8000K. A customized red/green phosphor film has also been shown to deliver 100% of NTSC color gamut for LCD display applications when combined with a blue LED.