Method for preparing efficient low voltage multilayer phosphor films

Abstract

The present invention relates to a method of preparing a multilayer phosphor (film) product on a substrate. The method comprises adding solid particulate precursor to a solution of an alkoxide precursor and a dopant precursor before hydrolysis is allowed to occur. The mixture is then allowed to hydrolyze, resulting in a sol-gel condensation reaction. The solid particulate precursor can be fumed silica, and acts as a nucleation site for the sol-gel reaction product. After the sol-gel reaction, the mixture is dried and fired to form a multilayer phosphor (film). The phosphor film is especially suitable for applications in which there is low voltage operation.

1. A method of preparing a multilayer phosphor product on a substrate comprising the steps of:
 (a) providing a solution comprising an alkoxide precursor and a dopant precursor;  
 (b) mixing said solution with a solid particle precursor wherein said solid particle precursor has an average particle size of about 7 nm and wherein said solid particle precursor reacts;  
 (c) inducing a sol-gel condensation reaction comprising said alkoxide precursor, said dopant precursor, and said solid particle precursor to form a sol-gel condensation reaction mixture;  
 (d) spreading the sol-gel condensation reaction mixture on a substrate;  
 (e) drying the sol-gel condensation reaction mixture;  
 (f) repeating steps (d) and (e) to produce a film; and  
 (g) heating the film.  
 
     
     
       2. The method according to  claim 1 , wherein said solution further comprises a hydrolysis agent. 
     
     
       3. The method according to  claim 1 , wherein a hydrolysis agent is added after said step (b). 
     
     
       4. The method according to  claim 3 , wherein said hydrolysis agent is added immediately before step (c). 
     
     
       5. The method according to  claim 1 , wherein said solution further comprises a reagent capable of inhibiting condensation reactions before step (b) in said solution. 
     
     
       6. The method according to  claim 2 , wherein said hydrolysis agent is selected from the group consisting of water, tetramethylammonium hydroxide, and mixtures thereof. 
     
     
       7. The method according to  claim 3 , wherein said hydrolysis agent is selected from the group consisting of water, tetramethylammonium hydroxide, and mixtures thereof. 
     
     
       8. The method according to  claim 1 , wherein said dopant precursor is an alkoxide, an acetate, an organometallic compound, an inorganic salt, or mixtures thereof. 
     
     
       9. The method according to  claim 1 , wherein said solid particle precursor is silica, metal oxide, metal sulfide, metal oxysulfide, metal halide, metal carbonate, metal phosphate, metal sulfate, GeO 2 , pure metal or mixtures thereof. 
     
     
       10. The method according to  claim 9 , wherein said solid particle precursor is fumed silica.