Method for Producing a Converter Element, Converter Element and Light Emitting Device

Abstract

A method for producing a converter element, a converter element and a light emitting device are disclosed. In an embodiment a converter element includes a cured layer having at least one phosphor and a cured polysiloxane powder, wherein the phosphor and the cured polysiloxane powder are embedded in a matrix material comprising a cured polysiloxane resin.

1 - 20 . (canceled) 
     
     
         21 . A converter element comprising:
 a cured layer comprising:
 at least one phosphor; and 
 a cured polysiloxane powder, 
 wherein the phosphor and the cured polysiloxane powder are embedded in a matrix material comprising a cured polysiloxane resin. 
   
     
     
         22 . The converter element according to  claim 21 , wherein the converter element has a total thickness of ≥10 μm. 
     
     
         23 . The converter element according to  claim 21 , wherein the converter element has a total thickness of ≥115 μm. 
     
     
         24 . The converter element according to  claim 21 , wherein the cured layer comprises at least a first layer and a second layer, and wherein the second layer is free of the at least one phosphor. 
     
     
         25 . The converter element according to  claim 24 , wherein the second layer has a thickness equal to or greater than a thickness of the first layer. 
     
     
         26 . The converter element according to  claim 24 , wherein the first layer comprises a thickness of ≤60 μm. 
     
     
         27 . The converter element according to  claim 21 , wherein the converter element is produced according to the following method:
 providing the at least one phosphor and a liquid polysiloxane resin;   preparing the cured polysiloxane powder from a first fraction of the liquid polysiloxane resin;   preparing a mixture including the at least one phosphor, the polysiloxane powder and a second fraction of the liquid polysiloxane resin;   casting and curing the mixture to a cured layer; and   singulating the cured layer.   
     
     
         28 . The converter element according to  claim 27 , wherein the liquid polysiloxane resin comprises the formula: 
       
         
           
           
               
               
           
         
         wherein Ti and T 2 represent terminal groups,    
         wherein R 1  to R 4 each represent side groups, and    
         wherein 0.8 ≤n≤1, 0≤m<0.2 and n+m=1. 
       
     
     
         29 . The converter element according to  claim 28 , wherein the terminal groups Ti and T 2  comprise a chemical reactive group chosen from the group consisting of alkoxy, vinyl, hydroxyl, carboxylic acid, ester, any other of the reactive functional groups know from the organic chemistry field, and combinations thereof. 
     
     
         30 . The converter element according to  claim 28 , wherein T 1  and T 2  are chosen from less reactive compounds chosen from the group consisting of hydrogen, methyl, ethyl or any alkyl, aryl groups, and combinations thereof. 
     
     
         31 . The converter element according to  claim 28 , wherein R 1  to R 4  are chosen—independently from each other—from the group consisting of methyl, methoxy, ethyl, ethoxy, phenyl, phenoxy, vinyl, and trifluoropropyl. 
     
     
         32 . The converter element according to  claim 28 , wherein the liquid polysiloxane resin comprises a methoxy methyl polysiloxane. 
     
     
         33 . The converter element according to  claim 32 , wherein a methoxy content is in an order of 10 to 50 wt %. 
     
     
         34 . A light emitting device comprising:
 an active electromagnetic radiation emitting layer sequence; and   the converter element according to  claim 21 ,   wherein the converter element is arranged on the active electromagnetic radiation emitting layer sequence.