Phosphor wheel, light source device, projection-type image display device, and method for manufacturing a phosphor wheel

Abstract

This fluorescent wheel comprises a rotatable substrate, a plurality of wavelength conversion layers disposed on the substrate, and an adhesive layer provided between the substrate and the plurality of wavelength conversion layers. At least a first wavelength conversion layer among the plurality of wavelength conversion layers is a sintered body-type wavelength conversion layer constituted by a sintered body of first wavelength conversion particles that convert excitation light to light of a first wavelength. At least a second wavelength conversion layer among the plurality of wavelength conversion layers is a mixed layer-type wavelength conversion layer which is a mixed layer of a support and second wavelength conversion particles that are filled in the support and that convert excitation light to light of a second wavelength differing from the first wavelength.

Description

Technical Field

[0001] The present disclosure relates to, for example, a phosphor wheel used in a light source device of a projection type video display device, a light source device, a projection type video display device, and a method for manufacturing a phosphor wheel.

Background Art

[0002] Conventional phosphor wheels using a fluorescent layer (wavelength conversion layer) have included a method consisting only of a so-called mixed layer type wavelength conversion layer in which phosphor particles are dispersed in a resin paste and applied, and a method consisting only of a sintered body type wavelength conversion layer made of a sintered body of phosphor particles.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

[0004] In the former phosphor wheel using a mixed layer type wavelength conversion layer, there are many selectable fluorescence wavelengths and it is excellent in cost, but it has problems in conversion efficiency and heat resistance. On the other hand, in the phosphor wheel using a sintered body type wavelength conversion layer, it is excellent in conversion efficiency and heat resistance, but cost is a problem.

[0005] An object of the present disclosure is to provide a phosphor wheel having an excellent balance between conversion efficiency, heat resistance, and cost.

[0006] The phosphor wheel according to this disclosure comprises a rotatable substrate, a plurality of wavelength conversion layers disposed on the substrate, and an adhesive layer provided between the substrate and the plurality of wavelength conversion layers. At least one of the plurality of wavelength conversion layers, the first wavelength conversion layer, is a sintered wavelength conversion layer composed of a sintered body of first wavelength conversion particles that wavelength-convert excitation light to light of a first wavelength. At least one of the plurality of wavelength conversion layers, the second wavelength conversion layer, is a mixed layer type wavelength conversion layer which is a mixed layer of a support and second wavelength conversion particles filled in the support that wavelength-convert excitation light to light of a second wavelength different from the first wavelength.

[0007] A method for manufacturing a phosphor wheel according to this disclosure includes the steps of: applying an adhesive layer to a substrate; attaching a sintered body of first wavelength conversion particles that wavelength-convert excitation light to light of a first wavelength to the substrate; curing the adhesive layer to form a sintered body type wavelength conversion layer; applying a mixed layer on the substrate on the same circumference as the sintered body type wavelength conversion layer, which is a mixture of second wavelength conversion particles that wavelength-convert excitation light to light of a second wavelength different from the first wavelength and a support; and curing the mixed layer to form a mixed layer type wavelength conversion layer.

[0008] The phosphor wheel according to this disclosure has a sintered wavelength conversion layer and a mixed-layer wavelength conversion layer. This allows for a balance between conversion efficiency, heat resistance, and cost. [Brief explanation of the drawing]

[0009] [Figure 1] This is a schematic plan view showing the planar configuration of the phosphor wheel according to Embodiment 1. [Figure 2] This is a flowchart showing the method for manufacturing a phosphor wheel according to Embodiment 1. [Figure 3] In the flowchart of the phosphor wheel manufacturing method shown in Figure 2, (a) is a plan view detailing the process of aligning a sintered wavelength conversion layer, which consists of a sintered body of wavelength conversion particles, on a substrate; (b) is a front view of (a); and (c) is a plan view showing the sintered wavelength conversion layer as seen through the substrate. [Figure 4]This is a plan view showing the positional relationship between the guide pins provided adjacent to the sintered wavelength conversion layer and the substrate attachment position during the process of aligning and attaching the sintered wavelength conversion layer to the substrate shown in Figure 3. [Figure 5] This is a front view showing the direction in which the sintered wavelength conversion layer is attached to the substrate in the process of aligning and attaching the sintered wavelength conversion layer to the substrate shown in Figure 3. [Figure 6] This diagram shows the configuration of a light source device using a phosphor wheel according to Embodiment 1. [Figure 7] This figure shows the configuration of a projection-type image display device equipped with a light source device using a phosphor wheel according to Embodiment 1. [Figure 8] This is a schematic plan view showing the planar configuration of the phosphor wheel according to Embodiment 2. [Figure 9] This figure shows the configuration of a light source device using a phosphor wheel according to Embodiment 2. [Figure 10] This figure shows the configuration of a projection-type image display device equipped with a light source device using a phosphor wheel according to Embodiment 2. [Figure 11] This is a schematic plan view showing the planar configuration of the phosphor wheel according to Embodiment 3. [Figure 12] This figure illustrates the alignment of the sintered wavelength conversion layer (with a center angle smaller than the design value) during the manufacturing of the phosphor wheel according to Embodiment 3. [Figure 13] This figure illustrates the alignment of the sintered wavelength conversion layer (with a center angle greater than the design value) during the manufacturing of the phosphor wheel according to Embodiment 3. [Modes for carrying out the invention]

[0010] The phosphor wheel according to the first aspect includes a rotatable substrate, a plurality of wavelength conversion layers disposed on the substrate, and an adhesive layer provided between the substrate and the plurality of wavelength conversion layers. At least the first wavelength conversion layer among the plurality of wavelength conversion layers is a sintered body type wavelength conversion layer composed of a sintered body of first wavelength conversion particles that wavelength-convert excitation light into light of a first wavelength. At least the second wavelength conversion layer among the plurality of wavelength conversion layers is a mixed layer type wavelength conversion layer that is a mixed layer of a support and second wavelength conversion particles filled in the support and that wavelength-convert excitation light into light of a second wavelength different from the first wavelength.

[0011] In the phosphor wheel according to the second aspect, in the first aspect, the mixed layer type wavelength conversion layer and the sintered body type wavelength conversion layer may be disposed adjacent to each other on the substrate.

[0012] In the phosphor wheel according to the third aspect, in the first or second aspect, at least one of the inner diameter or the outer diameter from the rotation center of the substrate of the first wavelength conversion layer and the second wavelength conversion layer may be different from each other.

[0013] In the phosphor wheel according to the fourth aspect, in any of the first to third aspects, the widths in the radial direction with respect to the rotation center of the first wavelength conversion layer and the second wavelength conversion layer may be different from each other.

[0014] In the phosphor wheel according to the fifth aspect, in any of the first to fourth aspects, the inner diameter of the first wavelength conversion layer from the rotation center of the substrate may be larger than the inner diameter of the second wavelength conversion layer from the rotation center of the substrate, and the outer diameter of the first wavelength conversion layer from the rotation center of the substrate may be smaller than the outer diameter of the second wavelength conversion layer from the rotation center of the substrate.

[0015] In the phosphor wheel according to the sixth aspect, in any of the first to fifth aspects, the substrate on which the plurality of wavelength conversion layers are disposed may have an opening on the same circumference with respect to the rotation center.

[0016] In the phosphor wheel according to the seventh aspect, in any of the first to fifth aspects, the phosphor wheel may have a reflection region on the same circumference with respect to the rotation center of the substrate on which a plurality of wavelength conversion layers are disposed.

[0017] The light source device according to the eighth aspect includes the phosphor wheel according to any of the first to seventh aspects.

[0018] The projection type video display device according to the ninth aspect includes the light source device according to the eighth aspect.

[0019] The method for manufacturing a phosphor wheel according to the tenth aspect includes a step of applying an adhesive layer to a substrate, a step of attaching a sintered wavelength conversion layer made of a sintered body of first wavelength conversion particles that convert excitation light into light of a first wavelength onto the substrate, a step of curing the adhesive layer to fix the sintered wavelength conversion layer, a step of applying a mixed layer obtained by mixing second wavelength conversion particles that convert excitation light into light of a second wavelength different from the first wavelength and a support on the substrate on the same circumference as the sintered wavelength conversion layer, and a step of curing the mixed layer to form a mixed layer type wavelength conversion layer.

[0020] In the method for manufacturing a phosphor wheel according to the eleventh aspect, in the step of forming the sintered wavelength conversion layer in the tenth aspect, guide pins for alignment are provided around the sintered body of the first wavelength conversion particles, and the substrate and the sintered body of the first wavelength conversion particles are relatively moved in a direction perpendicular to the bonding surface along the guide pins, and the sintered body of the first wavelength conversion particles may be attached to the portion of the substrate where the adhesive layer is applied.

[0021] In the method for manufacturing a phosphor wheel according to the twelfth aspect, in the step of forming the mixed layer type wavelength conversion layer in the eleventh aspect, the portion corresponding to the guide pin may be removed, and a mixed layer obtained by mixing the second wavelength conversion particles and the support may be applied to a portion adjacent to the sintered body of the first wavelength conversion particles on the substrate.

[0022] The embodiments will be described in detail below, with reference to the drawings as appropriate. However, unnecessarily detailed explanations may be omitted. For example, detailed explanations of already well-known matters and redundant explanations of substantially identical components may be omitted. This is to avoid the following explanation becoming unnecessarily verbose and to facilitate understanding for those skilled in the art. Also, substantially identical components are denoted by the same reference numerals in the drawings.

[0023] The attached drawings and the following description are provided to enable a person skilled in the art to fully understand this disclosure, and are not intended to limit the subject matter described in the claims.

[0024] (Embodiment 1) [1-1 Configuration of the phosphor wheel] The configuration of the phosphor wheel 2 according to Embodiment 1 will be described in detail below. Figure 1 is a schematic plan view showing the planar configuration of the phosphor wheel 2 according to Embodiment 1. As shown in Figure 1, the phosphor wheel 2 according to Embodiment 1 comprises a rotatable substrate 201, a plurality of wavelength conversion layers 204a, 204b, 205a, 205b, and an adhesive layer 202 (reflection layer) provided between the substrate 201 and the plurality of wavelength conversion layers 204a, 204b, 205a, 205b. The plurality of wavelength conversion layers 204a, 204b, 205a, 205b are arranged on the substrate 201 and wavelength convert the same excitation light into light of multiple different wavelengths. Furthermore, the plurality of wavelength conversion layers 204a, 204b, 205a, 205b include sintered body type wavelength conversion layers 204a, 204b and mixed layer type wavelength conversion layers 205a, 205b. The sintered wavelength conversion layers 204a and 204b are composed of sintered bodies of first wavelength conversion particles that convert excitation light to light of a first wavelength. The mixed layer wavelength conversion layers 205a and 205b are mixed layers of a support and second wavelength conversion particles packed into the support that convert excitation light to light of a second wavelength.

[0025] This phosphor wheel 2 has sintered wavelength conversion layers 204a and 204b and mixed layer wavelength conversion layers 205a and 205b, thus offering an excellent balance between conversion efficiency, heat resistance, and cost.

[0026] The following describes each member constituting the phosphor wheel 2.

[0027] <Substrate> The substrate 201 may be, for example, a substrate made of aluminum with excellent heat dissipation. Note that the substrate 201 is not limited to aluminum and may be other metals. Further, it may be a transmissive substrate such as glass or sapphire, or a transmissive substrate such as glass or sapphire provided with a reflection region. The substrate 201 is provided with a motor mounting hole 208 for mounting a motor for rotation. Also, it may be mounted to the motor by a method other than the motor mounting hole 208.

[0028] <Wavelength conversion layer> The wavelength conversion layer includes sintered body type wavelength conversion layers 204a and 204b and mixed layer type wavelength conversion layers 205a and 205b. These wavelength conversion layers 204a, 204b, 205a, and 205b are arranged on the substrate 201 on the same circumference from the rotation center of the substrate 201. Further, the same circumference may have openings 206a and 206b. Alternatively, as shown in Embodiment 2 described later, a reflection region may be provided instead of the openings. The sintered body type wavelength conversion layers 204a and 204b and the mixed layer type wavelength conversion layers 205a and 205b may be adjacent to each other on the same circumference, or may be adjacent to each other with the openings 206a and 206b interposed therebetween. Note that since the temperature rises when the sintered body type wavelength conversion layers 204a and 204b and the mixed layer type wavelength conversion layers 205a and 205b overlap, they may be adjacent to each other with a slight gap.

[0029] At least one of the inner diameters r1, R1 and the outer diameters r2, R2 from the rotation center of the substrate of the mixed layer type wavelength conversion layers 205a and 205b and the sintered body type wavelength conversion layers 204a and 204b may be different. For example, in the example shown in FIG. 1, the inner diameter R1 of the sintered body type wavelength conversion layers 204a and 20<b is smaller than the inner diameter r1 of the mixed layer type wavelength conversion layers 205a and 205b (R1 < r1), and the outer diameter R2 of the sintered body type wavelength conversion layers 204a and 204b is larger than the outer diameter r2 of the mixed layer type wavelength conversion layers 205a and 205b (R2 > r2).

[0030] Furthermore, the radial widths of the mixed-layer type wavelength conversion layers 205a and 205b and the sintered-body type wavelength conversion layers 204a and 204b from the rotation center of the substrate 201 may differ. For example, in the example shown in Figure 1, the radial width (r2-r1) of the mixed-layer type wavelength conversion layers 205a and 205b is narrower than the radial width (R2-R1) of the sintered-body type wavelength conversion layers 204a and 204b, where (r2-r1) < (R2-R1).

[0031] By setting any of the above conditions, at least one set of radial positions (r1, r2, R1, R2) between the mixed-layer wavelength conversion layers 205a, 205b and the sintered-body wavelength conversion layers 204a, 204b can be made different. This allows the guide pins provided around the sintered body of the first wavelength conversion particles to be positioned radially offset from the location where the mixed-layer wavelength conversion layers are provided during the manufacturing of the phosphor wheel. This facilitates the alignment of the sintered-body wavelength conversion layers 204a, 204b when they are bonded to the substrate.

[0032] <Sintered Wavelength Conversion Layer> The sintered wavelength conversion layers 204a and 204b are composed of sintered bodies of first wavelength conversion particles that wavelength-convert excitation light to light of a first wavelength.

[0033] <First wavelength conversion particle> The first wavelength-converting particle is a so-called phosphor particle, which may be, for example, a particle with a garnet structure. The chemical formula of the above garnet structure is, for example, Y3Al5O, which wavelength-converts blue excitation light to yellow fluorescence. 12 For example, Lu3Al5O, which converts blue excitation light to green fluorescence. 12 It may also be (Y,Lu)3Al5O, which is a mixture of these. 12 The activator may be, for example, Ce or Gd. Alternatively, it may be a particle that converts blue excitation light into fluorescence other than the aforementioned yellow or green.

[0034] <Mixed-layer type wavelength conversion layer> The mixed-layer type wavelength conversion layers 205a and 205b are mixed layers of a support and a second wavelength conversion particle packed into the support, which wavelength-converts excitation light to light of a second wavelength.

[0035] <Second wavelength conversion particle> The second wavelength-converting particle is a so-called phosphor particle, and may, for example, be a garnet-structured particle, similar to the first wavelength-converting particle. The chemical formula of the above garnet structure is, for example, Y3Al5O, which wavelength-converts blue excitation light to yellow fluorescence. 12 For example, Lu3Al5O, which converts blue excitation light to green fluorescence. 12 It may also be a mixture of these, (Y,Lu)3Al5O 12 It may also be the activator, for example, Ce or Gd. Alternatively, it may be a particle that converts blue excitation light into fluorescence other than the aforementioned yellow or green. By changing the structure, composition, etc., the first and second wavelengths converted in the first and second wavelength conversion particles can be varied in various ways.

[0036] <Support> The support is a medium in which the second wavelength conversion particles are dispersed, and may be, for example, a heat-resistant transparent resin such as silicone or silsesquioxane, or glass such as silicon dioxide or silicate glass.

[0037] <Adhesive layer> The adhesive layer 202 is provided between the substrate 201 and the sintered wavelength conversion layers 204a, 204b and the mixed-layer wavelength conversion layers 205a, 205b. The adhesive layer 202 is provided to bond the sintered wavelength conversion layers 204a, 204b to the substrate 201 and is a reflective layer that reflects the first light produced by wavelength conversion in the sintered wavelength conversion layers 204a, 204b and the second light produced by wavelength conversion in the mixed-layer wavelength conversion layers 205a, 205b. The reflective layer also reflects excitation light that was not absorbed by the sintered wavelength conversion layers 204a, 204b and the mixed-layer wavelength conversion layers 205a, 205b. The excitation light reflected in the reflective layer is absorbed again in the sintered wavelength conversion layers 204a, 204b or the mixed-layer wavelength conversion layers 205a, 205b and converted back into the first or second light. This improves the efficiency of wavelength conversion in the sintered body type wavelength conversion layers 204a and 204b and the mixed-layer type wavelength conversion layers 205a and 205b. The inner and outer diameters of the adhesive layer 202 are approximately the same as the inner diameter R1 and outer diameter R2 of the sintered body type wavelength conversion layers 204a and 204b, respectively. That is, the width of the adhesive layer 202 is approximately the same as the width of the sintered body type wavelength conversion layers 204a and 204b, and is larger than the width of the mixed-layer type wavelength conversion layers 205a and 205b.

[0038] <Opening> There may be one or more openings 206. If openings 206 are provided, the excitation light will pass through the openings 206, so blue light will be used as the excitation light.

[0039] <Method for manufacturing phosphor wheels> Figure 2 is a flowchart showing the method for manufacturing a phosphor wheel according to Embodiment 1. The method for manufacturing a phosphor wheel according to Embodiment 1 includes the following steps. (1) Apply an adhesive layer to the substrate (S01). The adhesive layer may be a mixed layer of a heat-resistant resin such as silicone or silsesquioxane filled with high-reflectivity particles. In this case, it will also function as a reflective layer. Alternatively, it may be a mixed layer of a heat-resistant resin such as silicone or silsesquioxane filled with high-thermal-conductivity particles. In this case, it will also function as a reflective layer. In this case, it has the effect of suppressing the temperature rise of the phosphor layer. Alternatively, both high-reflectivity and high-thermal-conductivity particles may be mixed, or a heat-resistant resin such as silicone or silsesquioxane without any particles may be used. (2) A sintered body of the first wavelength conversion particle, which converts the excitation light to light of the first wavelength, is attached to the substrate (S02). The attachment of the sintered body of the first wavelength conversion particle will be described later. (3) The adhesive layer is cured to fix the sintered wavelength conversion layer (S03). (4) A mixed layer is applied to the substrate on the same circumference as the sintered wavelength conversion layer, by mixing a second wavelength conversion particle that converts the excitation light to light of a second wavelength with a support (S04). (5) The mixed layer is cured to form a mixed layer type wavelength conversion layer (S05).

[0040] Through the above steps, a phosphor wheel according to Embodiment 1 is obtained.

[0041] <Step of attaching the sintered body of the first wavelength conversion particle> Figure 3 is a flowchart illustrating the manufacturing method of the phosphor wheel shown in Figure 2. Figure 3(a) is a plan view detailing the process of aligning and attaching a sintered wavelength conversion layer 204, which is made up of a sintered body of first wavelength conversion particles, to a substrate. Figure 3(b) is a front view of Figure 3(a), and Figure 3(c) is a plan view showing the sintered wavelength conversion layer 204 through the substrate.

[0042] As shown in Figure 3, in the process of attaching the sintered wavelength conversion layer 204 to the substrate 201, guide pins 211, 212a, 212b, and 212c are used to align the sintered wavelength conversion layer 204 to the substrate 201. The guide pins 211, 212a, 212b, and 212c are provided on the attachment base 210. Guide pin 211 is positioned to pass through the motor mounting hole 208 of the substrate 201. Guide pin 212a is positioned at the left end of the sintered wavelength conversion layer 204 and to pass through the opening 206 of the substrate 201. Guide pins 212b and 212c are positioned on both sides of the right end of the sintered wavelength conversion layer 204. The height of guide pins 212b and 212c is lower than the height of the sintered wavelength conversion layer 204, for example, by several tens of micrometers, as shown in Figure 3(b). Alternatively, guide pins 211, 212a, 212b, and 212c may be provided by means other than the adhesive base 210.

[0043] Figure 4 is a plan view showing the positional relationship between the guide pins 212a, 212b, and 212c, which are provided adjacent to the sintered wavelength conversion layer 204, and the attachment position on the substrate 201 in the process of aligning the sintered wavelength conversion layer 204 on the substrate 201 of Figure 3. Figure 5 is a front view showing the direction in which the sintered wavelength conversion layer 204 is attached to the substrate 201 in the process of aligning and attaching the sintered wavelength conversion layer 204 on the substrate 201 of Figure 3.

[0044] The process of attaching the sintered wavelength conversion layer 204 to the substrate 201 is performed by moving the substrate 201 and the sintered wavelength conversion layer 204 relative to each other in the Z direction, thereby attaching the sintered wavelength conversion layer 204 to the adhesive layer 202 of the substrate 201.

[0045] The guide pin 212a at the left end of the sintered wavelength conversion layer 204 is positioned to penetrate the opening 206 of the substrate 201, while the guide pins 212b and 212c at the right end are positioned to sandwich the area where the mixed-layer wavelength conversion layer is to be provided. Furthermore, the height of the right-end guide pins 212b and 212c is lower than the height of the sintered wavelength conversion layer 204, for example, by several tens of micrometers. Therefore, as shown in Figure 5, even when the substrate 201 and the sintered wavelength conversion layer 204 are moved relative to each other in the Z direction to attach the sintered wavelength conversion layer 204 to the adhesive layer 202 of the substrate 201, the guide pins 212b and 212c do not come into contact with the substrate 201. This suppresses the subsequent impact on the area where the mixed-layer wavelength conversion layer is to be provided. Moreover, this phosphor wheel manufacturing method allows for the formation of both a sintered wavelength conversion layer and a mixed-layer wavelength conversion layer. This allows for a balance between conversion efficiency, heat resistance, and cost.

[0046] [1-2 Light source device] The details of the light source device 11 using the phosphor wheel 2 according to Embodiment 1 will be described below. Figure 6 is a diagram showing the configuration of the light source device 11 using the phosphor wheel 2 according to Embodiment 1. From here on, the explanation will be based on the phosphor wheel 2 according to Embodiment 1 shown in Figure 1.

[0047] The blue wavelength laser light emitted from multiple laser light sources 1101 is collimated by multiple collimator lenses 1102, each of which is provided in relation to a specific laser light source 1101. The collimated blue light is then incident on a subsequent convex lens 1103, reducing its beam width, and then incident on a subsequent diffuser plate 1104, where it is diffused and its uniformity is improved. The blue light with improved uniformity is then incident on a subsequent concave lens 1105, where it is made into a parallel beam.

[0048] The blue light, which has been parallelized by the concave lens 1105, enters the color separation and synthesis mirror 1106, which is positioned at an angle of approximately 45 degrees with respect to the optical axis, changing the direction of light propagation by 90 degrees before entering the subsequent convex lens 1107. The color separation and synthesis mirror 1106 has spectral characteristics that reflect light in the wavelength range of blue light emitted from the laser light source 1101, and allow light in the wavelength range of fluorescence, which is the excitation light blue light emitted from the laser light source 1101 that has been wavelength-converted by the phosphor wheel 2 described later, to pass through.

[0049] In this example, the color separation and synthesis mirror 1106 is assumed to have spectral characteristics that focus on the wavelength characteristics of blue light from a laser light source and the wavelength-converted fluorescence. However, it is not limited to this, and for example, it may have spectral characteristics that focus on polarization and wavelength. Specifically, the polarization direction of the blue light from the laser light source may be adjusted to the same direction, focusing on the polarization direction of the laser light source. This may result in spectral characteristics that focus on polarization and wavelength, such that it reflects light in the blue wavelength range and polarization direction from the laser light source and transmits light in the wavelength range of the wavelength-converted fluorescence.

[0050] The blue light incident on the convex lens 1107, in combination with the subsequent convex lens 1108, is incident on the wavelength conversion layers 204a, 204b, 205a, 205b and apertures 206a, 206b, which are located on the same radius and provided on the subsequent phosphor wheel 2.

[0051] A motor 309 is provided in the phosphor wheel 2. The blue excitation light, focused by convex lenses 1107 and 1108, is positioned around the rotation axis of the motor 309 so as to be incident on the same radial region from the rotation center where the wavelength conversion layers 204a, 204b, 205a, and 205b and the apertures 206a and 206b are located.

[0052] First, the blue light focused onto the wavelength conversion layers 204a, 204b, 205a, and 205b of the phosphor wheel 2 by the convex lenses 1107 and 1108 is wavelength-converted to fluorescence, and its direction of propagation is changed by 180 degrees. It is then incident on the convex lenses 1108 and 1107 in that order, and the light beam is made parallel. The fluorescence wavelength-converted by the phosphor wheel 2 is combined with the blue light emitted from the laser light source 1101 to optimize the wavelength range so that it forms, for example, white light.

[0053] The fluorescence, which is emitted from the convex lens 1107 and converted into a parallel beam, is then incident again on the color separation and synthesis mirror 1106. As mentioned above, the color separation and synthesis mirror 1106 has the characteristic of transmitting light in the wavelength range of fluorescence and is positioned at an angle of approximately 45 degrees with respect to the optical axis, so it transmits the fluorescence without changing its direction of propagation.

[0054] Next, the blue light from the laser light source 1101, focused at the apertures 206a and 206b of the phosphor wheel 2, passes through the phosphor wheel 2 and is then parallelized by the convex lenses 1121 and 1122 in the subsequent stage. Subsequently, a relay lens system consisting of three mirrors 1123, 1125, and 1127 and three convex lenses 1124, 1126, and 1128, located in the subsequent stage, guides the light to the color separation and synthesis mirror 1106 so that it is parallelized and incident from a direction 180 degrees opposite to the direction in which the light from the laser light source 1101 is incident.

[0055] In this example, a relay optical system was constructed using three mirrors and three convex lenses, but other configurations may be used as long as they provide similar performance.

[0056] Since the color separation and synthesis mirror 1106 has the property of reflecting blue light from the laser light source 1101, the blue light incident on the color separation and synthesis mirror 1106 from the convex lens 1128 is reflected with its direction of propagation changed by 90 degrees.

[0057] In this way, with the above configuration, the fluorescence and blue light that are time-resolved and combined by the color separation and synthesis mirror 1106 are incident on the convex lens 1109, which is the subsequent optical system.

[0058] The time-resolved fluorescence and blue light incident on the convex lens 1109 from the color separation and synthesis mirror 1106 are focused by the convex lens 1109 near the incident end of the rod integrator 1111, which will be described later. The light emitted from the convex lens 1109 is incident on the color-filtered wheel 1110 before it is incident on the rod integrator 1111. The color-filtered wheel 1110 is synchronized with the phosphor wheel 2 using a synchronization circuit (not shown), and is composed of multiple filters with spectral characteristics that transmit some or all wavelengths of blue light and fluorescence, in accordance with the characteristics of the optical system.

[0059] The color-filtered wheel 1110 has a region that transmits the wavelength range of the yellow fluorescence from the phosphor wheel 2 as is, a region that transmits the wavelength range of the green fluorescence from the phosphor wheel 2 as is, a region that reflects the green wavelength light and transmits the red wavelength light within the fluorescence, and a region that transmits the blue wavelength light that passes through the apertures 206a and 206b from the phosphor wheel 2 as is. As the phosphor wheel 2 and the color-filtered wheel 1110 rotate in synchronously, light with different wavelength ranges in a time series is focused near the incident end of the rod integrator 1111. Note that the configuration of the color-filtered wheel is not limited to the above configuration and may be changed as appropriate according to the specifications of the phosphor wheel, light source device, and projection-type image display device.

[0060] Light of different wavelengths, incident on the rod integrator 1111, is homogenized by the rod integrator and emitted from the output end. In the explanation in Figure 6, the wheel with color filter 1110 is placed near the incident side of the rod integrator, but it may also be placed near the output side.

[0061] <Effects> In the light source device 11 using the phosphor wheel 2 according to Embodiment 1, it is possible to balance conversion efficiency, heat resistance, and cost.

[0062] [1-3 Projection-type image display device] The details of the projection-type image display device 14 employing the light source device 11 using the phosphor wheel 2 according to Embodiment 1 will be described below. Figure 7 is a diagram showing the configuration of the projection-type image display device 14 employing the light source device 11 using the phosphor wheel 2 according to Embodiment 1. As the configuration of the light source device 11 using the phosphor wheel 2 according to Embodiment 1 has been described above, the explanation will be omitted here, and the behavior of the light after it is emitted from the rod integrator 1111 will be described in detail.

[0063] The light emitted from the rod integrator 1111 is mapped to the DMD 1421, which will be described later, by a relay lens system consisting of convex lenses 1401, 1402, and 1403.

[0064] Light that passes through convex lenses 1401, 1402, and 1403 and enters the total internal reflection prism 1411 enters the minute gap 1412 of the total internal reflection prism 1411 at an angle greater than the total internal reflection angle, and is reflected, thereby changing the direction of light propagation and entering the DMD 1421.

[0065] The DMD1421 changes the direction of a minute mirror in response to a signal from a video circuit (not shown), in sync with the colored light emitted by the combination of the phosphor wheel 2 and the color filter wheel 1110, and emits the light with the direction of propagation changed accordingly. The light whose direction of propagation has been changed in the DMD1421 in response to the video signal is incident on the minute gap 1412 of the total internal reflection prism 1411 at an angle less than or equal to the total internal reflection angle, passes through it, is incident on the projection lens 1431, and is projected onto a screen (not shown).

[0066] <Effects> In the projection-type image display device 14 using the light source device 11 with the phosphor wheel 2 according to Embodiment 1, it is possible to balance conversion efficiency, heat resistance, and cost.

[0067] (Embodiment 2) [2-1 Configuration of the phosphor wheel] The configuration of the phosphor wheel 2a according to Embodiment 2 will be described in detail below. Figure 8 is a front view of the phosphor wheel 2a according to Embodiment 2. In the following description, the novel elements in the phosphor wheel 2a according to Embodiment 2 will be described, and the components described in Figure 1 will not be described.

[0068] As shown in Figure 8, the phosphor wheel 2a according to Embodiment 2 differs from the phosphor wheel according to Embodiment 1 in that it has reflective regions 213a and 213b instead of an opening. The reflective regions 213a and 213b directly reflect the excitation light. The reflective regions 213a and 213b can be configured as regions within the adhesive layer (reflective layer) formed on the substrate 201 where the wavelength conversion layers 204a, 204b, 205a, and 205b are not formed.

[0069] The reflective regions 213a and 213b are provided in substantially the same positions as the openings of the phosphor wheel according to Embodiment 1, but are not limited to this. The reflective regions 213a and 213b are not limited to two, but may be two or more.

[0070] When a reflective region is provided instead of an aperture in this way, all light is obtained as reflected light. Therefore, there is no need to consider the optical path for photosynthesis with the excitation light that has passed through the aperture and the reflected light whose wavelength has been changed.

[0071] [2-2 Light source device] The following describes the details of the light source device 12 in the second example using the phosphor wheel according to Embodiment 2. Figure 9 shows the configuration of the light source device 12 in the second example using the phosphor wheel 2a according to Embodiment 2. The following explanation will use the phosphor wheel 2a according to Embodiment 2 shown in Figure 8.

[0072] Blue wavelength laser light emitted from multiple laser light sources 1201 is collimated by multiple collimator lenses 1202, each of which is provided in conjunction with a separate laser light source 1201. The collimated blue light is then incident on a subsequent convex lens 1203, reducing its beam width, and then incident on a subsequent diffuser plate 1204 where it is diffused, improving the uniformity of the light. The blue light, whose uniformity has been improved by the diffuser plate 1204, is then incident on a subsequent concave lens 1205, where it is made into a parallel beam.

[0073] Furthermore, with the concave lens 1205 emitted, the optical system up to the concave lens 1205 is adjusted so that the polarization direction of the laser light becomes S-polarization with respect to the polarization and color separation / combination mirror 1206, which will be described later.

[0074] The blue light, which has been parallelized by the concave lens 1205, is incident on the polarization and color separation and synthesis mirror 1206, which is positioned at approximately 45 degrees with respect to the optical axis, changing the direction of light propagation by 90 degrees before being incident on the subsequent λ / 4 wave plate 1207. The polarization and color separation and synthesis mirror 1206 has spectral characteristics such that it reflects S-polarized light in the blue wavelength range emitted from the laser light source 1201, and also passes P-polarized light in the blue wavelength range emitted from the laser light source 1201 and light in the fluorescence wavelength range, which is the blue light that is the excitation light from the laser light source 1201, wavelength-converted by the phosphor wheel 2a described later.

[0075] The polarization direction of the blue light from the laser light source 1201 incident on the λ / 4 wave plate 1207 is rotated to change it to circularly polarized light.

[0076] Light emitted from the λ / 4 wave plate 1207 enters the convex lens 1208 and, in combination with the subsequent convex lens 1209, enters the reflection regions 213a and 213b and the wavelength conversion layers 204a, 204b, 205a, and 205b provided on the subsequent phosphor wheel 2a. The phosphor wheel 2a is equipped with a motor 409, and around its axis of rotation, the blue excitation light focused by the convex lenses 1208 and 1209 is arranged to enter the reflection regions 213a and 213b and the wavelength conversion layers 204a, 204b, 205a, and 205b.

[0077] First, the blue light focused onto the wavelength conversion layers 204a, 204b, 205a, and 205b of the phosphor wheel 2a by the convex lenses 1208 and 1209 is converted into fluorescence, and its direction of propagation is changed by 180 degrees. It then enters the convex lenses 1209 and 1208 in the same order, and is made into a parallel beam. The fluorescence whose wavelength is converted by the phosphor wheel 2a is optimized in its respective wavelength range so that it is combined with the blue light emitted from the laser light source 1201 to form white light.

[0078] The fluorescence, which is parallelized by the convex lens 1208 and emitted, passes through the λ / 4 wave plate 1207 and is again incident on the polarization and color separation and synthesis mirror 1206, which is positioned at a 45-degree angle to the optical axis. As mentioned above, the polarization and color separation and synthesis mirror 1206 has the property of transmitting light in the wavelength range of fluorescence, so it passes the fluorescence without changing the direction of the light, and the fluorescence is incident on the subsequent convex lens 1210.

[0079] Next, the blue light from the laser light source 1201, focused on the reflective regions 213a and 213b of the phosphor wheel 2a, is reflected by the reflective regions 213a and 213b of the phosphor wheel 2a, changing its direction of travel by 180 degrees, and then incident on the convex lenses 1209 and 1208 in that order, becoming a parallel beam of light.

[0080] The blue light, which has been made into a parallel beam by the convex lenses 1209 and 1208, is incident on the subsequent λ / 4 wave plate 1207, where its polarization direction is rotated and it is converted to P-polarized light before being emitted.

[0081] P-polarized light in the blue wavelength range emitted from the λ / 4 wave plate 1207 is incident on the polarization and color separation and synthesis mirror 1206, which is positioned at approximately a 45-degree angle to the optical axis. The polarization and color separation and synthesis mirror 1206 has the characteristic of reflecting S-polarized light in the blue wavelength range emitted from the laser light source 1201, and transmitting P-polarized light in the blue wavelength range emitted from the laser light source 1201 and light in the fluorescence wavelength range that has been wavelength-converted by the phosphor wheel 2a. Therefore, the P-polarized light in the blue wavelength range emitted from the λ / 4 wave plate 1207 passes through without changing the direction of light propagation and is incident on the subsequent convex lens 1210.

[0082] As the phosphor wheel 2a rotates, fluorescence and blue light are incident on the convex lens 1210 in a time series and are focused near the incident end of the rod integrator 1212, which will be described later. The light focused by the convex lens 1210 is incident on the color filter wheel 1211. The color filter wheel 1211 has the same configuration as the color filter wheel 1211 used in the light source device 11 employing the phosphor wheel according to Embodiment 1. As the phosphor wheel 2a and the color filter wheel 1211 rotate in synchronously, light with different wavelength ranges is focused in a time series near the incident end of the rod integrator 1212.

[0083] Light of different wavelengths, incident on the rod integrator 1212, is homogenized by the rod integrator and emitted from the output end. In the explanation in Figure 9, the wheel with a color filter 1211 is placed near the incident side of the rod integrator, but it may also be placed near the output side.

[0084] <Effects> In the light source device 12 using the phosphor wheel 2a according to Embodiment 2, it is possible to balance conversion efficiency, heat resistance, and cost.

[0085] [2-3 Projection-type image display device] The following describes the details of the projection-type image display device 15 employing a light source device 12 using a phosphor wheel 2a according to Embodiment 2. Figure 10 is a diagram showing the configuration of the projection-type image display device 15 employing a light source device 12 using a phosphor wheel 2a according to Embodiment 2.

[0086] The configuration of the light source device 12 using the phosphor wheel according to Embodiment 2 has been described above, so its explanation is omitted here. Also, the behavior of light after the rod integrator 1212 is emitted in the projection-type image display device 15 shown in Figure 10 is substantially the same as the behavior of light after the rod integrator 1111 is emitted in the projection-type image display device 14 shown in Figure 7, so the same reference numerals are used and their explanation is omitted here.

[0087] <Effects> In the projection-type image display device 15 using the light source device 12 with the phosphor wheel 2a according to Embodiment 2, it is possible to balance conversion efficiency, heat resistance, and cost.

[0088] (Embodiment 3) [3-1 Configuration of the phosphor wheel] The configuration of the phosphor wheel 2b according to Embodiment 3 will be described in detail below. Components identical to those in Embodiments 1 and 2 are denoted by the same reference numerals and their description is omitted. Figure 11 is a schematic plan view showing the planar configuration of the phosphor wheel 2b according to Embodiment 3. As shown in Figure 11, the phosphor wheel 2b comprises a rotatable substrate 201, a plurality of wavelength conversion layers 224a, 224b, 225a, 225b, and an adhesive layer 202 (reflective layer) provided between the substrate 201 and the plurality of wavelength conversion layers 224a, 224b, 225a, 225b.

[0089] Multiple wavelength conversion layers 224a, 224b, 225a, and 225b are arranged on the substrate 201 and convert the same excitation light into light of multiple different wavelengths. The multiple wavelength conversion layers 224a, 224b, 225a, and 225b are sintered body type wavelength conversion layers 224a and 224b and mixed layer type wavelength conversion layers 225a and 225b. The sintered body type wavelength conversion layers 224a and 224b are composed of sintered bodies of first wavelength conversion particles that convert excitation light into light of a first wavelength. The mixed layer type wavelength conversion layers 225a and 225b are mixed layers of a support and second wavelength conversion particles filled in the support that convert excitation light into light of a second wavelength.

[0090] This phosphor wheel 2b has sintered wavelength conversion layers 224a and 224b and mixed layer wavelength conversion layers 225a and 225b, thus offering an excellent balance between conversion efficiency, heat resistance, and cost.

[0091] The following describes each component that makes up this phosphor wheel 2b.

[0092] <Wavelength conversion layer> The wavelength conversion layers are sintered wavelength conversion layers 224a and 224b and mixed layer wavelength conversion layers 225a and 225b. These wavelength conversion layers 224a, 224b, 225a, and 225b are arranged on the substrate 201 on the same circumference from the rotation center of the substrate 201. In addition, openings 206a and 206b are provided on the same circumference, similar to Embodiment 1. Alternatively, as shown in Embodiment 2, a reflective region can be provided instead of an opening to form a phosphor wheel. The sintered wavelength conversion layers 224a and 224b and the mixed layer wavelength conversion layers 225a and 225b may be adjacent to each other on the same circumference, or they may be adjacent with the openings 206a and 206b in between. Note that if the sintered wavelength conversion layers 224a and 224b and the mixed layer wavelength conversion layers 225a and 225b overlap, the temperature will be high, so they may be placed adjacent with a small gap between them.

[0093] The mixed-layer type wavelength conversion layers 225a, 225b and the sintered-body type wavelength conversion layers 224a, 224b may differ in at least one of their inner diameters r3, R3 and outer diameters r4, R4 from the rotation center of the substrate. In Embodiment 3, unlike Embodiments 1 and 2, as shown in Figure 11, the inner diameter R3 of the sintered-body type wavelength conversion layers 224a, 224b is larger than the inner diameter r3 of the mixed-layer type wavelength conversion layers 225a, 225b (R3>r3), and the outer diameter R4 of the sintered-body type wavelength conversion layers 224a, 224b is smaller than the outer diameter r4 of the mixed-layer type wavelength conversion layers 225a, 225b (R4>r3). <r4)。

[0094] Furthermore, the radial widths of the mixed-layer type wavelength conversion layers 225a and 225b and the sintered-body type wavelength conversion layers 224a and 224b from the rotation center of the substrate 201 may differ. In Embodiment 3, unlike in Embodiments 1 and 2, as shown in Figure 11, the radial width (r4-r3) of the mixed-layer type wavelength conversion layer 225a is wider than the radial width (R4-R3) of the sintered-body type wavelength conversion layers 224a and 224b, and the relationship (r4-r3)>(R4-R3) is met.

[0095] By having at least one of the inner diameters R3, r3 of the sintered wavelength conversion layers 224a, 224b and the mixed-layer wavelength conversion layers 225a, 225b, and the outer diameters R4, r4 of the sintered wavelength conversion layers 224a, 224b and the mixed-layer wavelength conversion layers 225a, 225b differ, it is possible to position the guide pins around the sintered body of the first wavelength conversion particles radially offset from the location where the mixed-layer wavelength conversion layer is provided during the manufacturing of the phosphor wheel. This makes it easier to align the sintered wavelength conversion layers 224a, 224b when bonding them to the substrate.

[0096] <Sintered Wavelength Conversion Layer> The sintered wavelength conversion layers 224a and 224b are composed of sintered bodies of first wavelength conversion particles that wavelength-convert excitation light to light of a first wavelength, similar to the sintered wavelength conversion layers 204a and 204b described in Embodiment 1.

[0097] <Mixed-layer type wavelength conversion layer> The mixed-layer type wavelength conversion layers 225a and 225b are, similar to the mixed-layer type wavelength conversion layers 205a and 205b described in Embodiment 1, mixed layers of a support and second wavelength conversion particles packed in the support that wavelength-convert excitation light to light of a second wavelength.

[0098] <Adhesive layer> The adhesive layer 202 is provided between the substrate 201 and the sintered wavelength conversion layers 224a, 224b and the mixed-layer wavelength conversion layers 225a, 225b. The adhesive layer 202 is provided to bond the sintered wavelength conversion layers 224a, 224b to the substrate 201 and is a reflective layer that reflects the first light produced by wavelength conversion in the sintered wavelength conversion layers 224a, 224b and the second light produced by wavelength conversion in the mixed-layer wavelength conversion layers 225a, 225b. The reflective layer also reflects excitation light that was not absorbed by the sintered wavelength conversion layers 224a, 224b and the mixed-layer wavelength conversion layers 225a, 225b. The excitation light reflected in the reflective layer is absorbed again in the sintered wavelength conversion layers 224a, 224b or the mixed-layer wavelength conversion layers 225a, 225b and converted back into the first or second light. This improves the wavelength conversion efficiency in the sintered wavelength conversion layers 224a and 224b and the mixed-layer wavelength conversion layers 225a and 225b. The inner and outer diameters of the adhesive layer 202 are approximately the same as the inner diameter r3 and outer diameter r4 of the mixed-layer wavelength conversion layers 225a and 225b, respectively. That is, the width of the adhesive layer 202 is approximately the same as the width of the mixed-layer wavelength conversion layers 225a and 225b, and is greater than the width of the sintered wavelength conversion layers 224a and 224b. Therefore, the adhesive layer 202 is exposed on both radial sides of the sintered wavelength conversion layers 224a and 224b.

[0099] <Method for manufacturing phosphor wheels> The method for manufacturing the phosphor wheel 2b according to Embodiment 3 includes the steps shown in the flowchart of Figure 2 described in Embodiment 1.

[0100] In step S01, an adhesive paste for forming an adhesive layer (reflective layer) is dispensed from the coating nozzle of the coating machine onto the portion of the substrate 201 where the sintered wavelength conversion layers 224a and 224b and the mixed-layer type wavelength conversion layers 225a and 225b are to be applied. The width of the adhesive layer can be controlled by the diameter of the coating nozzle that dispenses the adhesive paste.

[0101] In step S02, the sintered wavelength conversion layers 224a and 224b are aligned and attached to the adhesive layer 202 applied to the substrate 201. Figures 12 and 13 illustrate the alignment of the sintered wavelength conversion layers during the manufacturing of the phosphor wheel according to Embodiment 3. Figure 12 shows the case where the center angle of the sintered wavelength conversion layer to be attached is smaller than the design value, and Figure 13 shows the case where it is larger than the design value. The figures show the vicinity of the sintered wavelength conversion layer 224a of the phosphor wheel 2b, but the same applies to the vicinity of the sintered wavelength conversion layer 224b.

[0102] If the center angle of the sintered wavelength conversion layer to be attached is smaller than the design value, when attempting to position the sintered wavelength conversion layer 224a in the center of the width of the adhesive layer 202, as shown in part A of Figure 12(a), the edge of the sintered wavelength conversion layer 224a does not reach the boundary between the adhesive layer 202 and the opening 206a. This creates a gap G between the edge of the sintered wavelength conversion layer 224a and its boundary, where the adhesive layer 202 is exposed. In this case, since the sintered wavelength conversion layer 224a is absent in the gap G and the adhesive layer 202 is exposed, the excitation light incident on the phosphor wheel 2b is reflected directly.

[0103] Figure 12(b) shows the case where the sintered wavelength conversion layer 224a is shifted in the direction of the opening 206a so that no gap G occurs, and the edge of the sintered wavelength conversion layer 224a is positioned at the boundary between the adhesive layer 202 and the opening 206a, and the sintered wavelength conversion layer 224a is attached. In this case, the sintered wavelength conversion layer 224a is shifted from the center of the width of the adhesive layer 202 in the direction of the rotation center of the substrate 201, especially on the side of the mixed layer type wavelength conversion layer 225a. However, as described above, the width of the adhesive layer 202 is wider than the sintered wavelength conversion layer 224a, so the entire back surface (the surface facing the substrate 201) of the sintered wavelength conversion layer 224a can be reliably bonded to the substrate 201 by the adhesive layer 202.

[0104] Furthermore, if the center angle of the sintered wavelength conversion layer to be attached is greater than the design value, and an attempt is made to position the sintered wavelength conversion layer 224a in the center of the width of the adhesive layer 202, the edge of the sintered wavelength conversion layer 224a will extend beyond the boundary between the adhesive layer 202 and the opening 206a, as shown in part A of Figure 13(a), and protrude into the opening 206a, creating a protruding portion P. When a protruding portion P occurs, the fluorescence generated in the protruding portion P by the excitation light will not be reflected by the adhesive layer 202 (reflection layer), resulting in a decrease in reflection efficiency. In addition, since the protruding portion P is not adhered by the adhesive layer 202, peeling of the sintered wavelength conversion layer 224a from the protruding portion P is likely to occur.

[0105] Figure 13(b) shows the case where the sintered wavelength conversion layer 224a is offset from the opening 206a toward the adhesive layer 202 so that no overhang P occurs, and the edge of the sintered wavelength conversion layer 224a is positioned at the boundary between the adhesive layer 202 and the opening 206a, and the sintered wavelength conversion layer 224a is attached. In this case, the sintered wavelength conversion layer 224a is offset from the center of the width of the adhesive layer 202 toward the outer circumference of the substrate 201, especially on the side of the mixed layer type wavelength conversion layer 225a. However, as described above, the width of the adhesive layer 202 is wider than the sintered wavelength conversion layer 224a, so the entire back surface of the sintered wavelength conversion layer 224a can be reliably bonded to the substrate 201 by the adhesive layer 202.

[0106] Thus, in the phosphor wheel 2b of Embodiment 3, the width of the adhesive layer 202 (reflective layer) is wider than the width of the sintered wavelength conversion layers 224a and 224b. Therefore, even if the dimensions of the sintered wavelength conversion layers 224a and 224b are smaller or larger than the design value, the entire back surface of the sintered wavelength conversion layers 224a and 224b can be reliably bonded to the substrate 201 while aligning the edges of the sintered wavelength conversion layers 224a and 224b with the boundary between the adhesive layer 202 and the opening 206a.

[0107] In step S04, a mixed layer is applied to form mixed-layer type wavelength conversion layers 225a and 225b on the cured adhesive layer 202 on the substrate 201. The width of the applied mixed layer can be controlled by the diameter of the application nozzle that dispenses the mixed paste. As described above, since the widths of the mixed-layer type wavelength conversion layers 225a and 225b are almost the same as the width of the adhesive layer 202, the application nozzle for applying the mixed layer can be shared with the application nozzle for applying the adhesive layer, which has the same diameter. By sharing the application nozzle between the adhesive layer application process (S01) and the mixed layer application process (S04), it is possible to prevent errors such as using the wrong application nozzle in the work process. In addition, since it is not necessary to prepare separate application nozzles for the adhesive layer application process (S01) and the mixed layer application process (S04), the cost of purchasing application nozzles can be reduced.

[0108] [3-2 Light source devices, projection-type image display devices] The phosphor wheel 2b according to Embodiment 3 can be used to configure a light source device and a projection-type image display device by replacing the phosphor wheel 2 of the light source device 11 (Figure 6) and projection-type image display device 14 (Figure 7) described in Embodiment 1. Also, as described in Embodiment 2, the phosphor wheel 2b according to Embodiment 3 can be configured as a phosphor wheel in which the openings 206a and 206b are replaced with reflective areas 213a and 213b. The phosphor wheel in which the openings 206a and 206b of the phosphor wheel 2b are replaced with reflective areas 213a and 213b can be used to configure a light source device and a projection-type image display device by replacing the phosphor wheel 2a of the light source device 12 (Figure 9) and projection-type image display device 15 (Figure 10) described in Embodiment 2. In the light source device and projection-type image display device using the phosphor wheel 2b according to Embodiment 3 (including a phosphor wheel in which the openings 206a and 206b are replaced with reflective regions 213a and 213b), a balance can be achieved between conversion efficiency, heat resistance, and cost, similar to the light source device 11 of Embodiment 1.

[0109] Furthermore, this disclosure includes appropriately combining any of the various embodiments and / or examples described above, and the effects of each embodiment and / or example can be achieved. [Industrial applicability]

[0110] The phosphor wheel according to this disclosure has a sintered wavelength conversion layer and a mixed-layer wavelength conversion layer. This allows for a balance between conversion efficiency, heat resistance, and cost. [Explanation of symbols]

[0111] 2, 2a, 2b Phosphor Wheel 201 circuit board 202 Adhesive layer 204, 204a, 204b, 224a, 224b Sintered Wavelength Conversion Layer 205a, 205b, 225a, 225b Mixed layer type wavelength conversion layer 206, 206a, 206b opening 208 motor mounting holes 210 Adhesive base 211 Guide pins 212a, 212b, 212c Guide pins 213a, 213b reflective area 11 Light source device 1101 Laser light source 1102 Collimator lens 1103 Convex lens 1104 Diffuser 1105 Concave lens 1106 Color Separation and Combination Mirror 1107 Convex lens 1108 Convex lens 309 Motor 1109 Convex lens 1110 Wheel with Color Filter 1111 Rod Integrator 1121 Convex lens 1122 Convex lens 1123 Miller 1124 Convex lens 1125 Mirror 1126 Convex lens 1127 Miller 1128 Convex lens 12 Light source device 1201 Laser light source 1202 Collimator Lens 1203 Convex lens 1204 Diffuser 1205 Concave lens 1206 Polarizing and color-separating composite mirror 1207 λ / 4 wave plate 1208 Convex lens 1209 Convex lens 409 Motor 1210 Convex Lens 1211 Wheel with Color Filter 1212 Rod Integrator 14, 15 Projection-type image display device 1401 Convex lens (relay lens) 1402 Convex lens (relay lens) 1403 Convex lens (relay lens) 1411 Total Internal Reflection Prism 1412 Micro-gap 1421 DMD 1431 Projection lens R1, R3, r1, r3 Inner diameter R2, R4, r2, r4 outer diameter

Claims

1. A rotatable circuit board, Multiple wavelength conversion layers arranged on the substrate, An adhesive layer provided between the substrate and the plurality of wavelength conversion layers, Equipped with, At least one of the plurality of wavelength conversion layers is a sintered wavelength conversion layer composed of a sintered body of first wavelength conversion particles that wavelength-convert excitation light to light of a first wavelength, At least the second wavelength conversion layer among the plurality of wavelength conversion layers is a mixed layer type wavelength conversion layer which is a mixed layer of a support and a second wavelength conversion particle filled in the support that wavelength converts the excitation light to light of a second wavelength different from the first wavelength. The adhesive layer also serves as a reflective layer that reflects light of the second wavelength, forming a phosphor wheel.

2. The phosphor wheel according to claim 1, wherein the first wavelength conversion layer and the second wavelength conversion layer are arranged adjacent to each other on the substrate.

3. The phosphor wheel according to claim 2, wherein the first wavelength conversion layer and the second wavelength conversion layer have at least one of their inner diameters or outer diameters from the rotation center of the substrate different from each other.

4. The phosphor wheel according to claim 2, wherein the first wavelength conversion layer and the second wavelength conversion layer have different radial widths from the rotation center of the substrate.

5. The phosphor wheel according to claim 2, wherein the inner diameter of the first wavelength conversion layer from the rotation center of the substrate is smaller than the inner diameter of the second wavelength conversion layer from the rotation center of the substrate, and the outer diameter of the first wavelength conversion layer from the rotation center of the substrate is larger than the outer diameter of the second wavelength conversion layer from the rotation center of the substrate.

6. The phosphor wheel according to claim 1, wherein the plurality of wavelength conversion layers are arranged on the substrate and the opening is located on the same circumference of the rotation center of the substrate.

7. The phosphor wheel according to claim 1, wherein the phosphor wheel has a reflection region on the same circumference of the rotation center of the substrate on which the plurality of wavelength conversion layers are arranged.

8. A light source device comprising a phosphor wheel according to any one of claims 1 to 7.

9. A projection-type image display device comprising the light source device described in claim 8.

10. A step of applying an adhesive layer to a substrate having an opening along a part of the circumferential direction, along the same circumferential direction as the opening, The steps include attaching a sintered body of first wavelength-converting particles that wavelength-converts excitation light to light of a first wavelength onto the substrate, The steps include curing the adhesive layer to form a sintered wavelength conversion layer, The process involves coating the substrate with a mixed layer on the same circumference as the sintered wavelength conversion layer, which is made by mixing a second wavelength conversion particle that converts the excitation light to light of a second wavelength different from the first wavelength with a support, and a support. The process involves curing the aforementioned mixed layer to form a mixed-layer type wavelength conversion layer, It has, In the step of attaching the first wavelength conversion particle sintered body, a first guide pin, whose height in the stacking direction is greater than that of the sintered wavelength conversion layer, and a second guide pin, whose height in the stacking direction is less than that of the sintered wavelength conversion layer, are provided around the first wavelength conversion particle sintered body for alignment purposes. The first guide pin penetrates the opening and runs along the edge of the sintered wavelength conversion layer and the opening, while the second guide pin is positioned at the other end of the sintered wavelength conversion layer. The substrate and the first wavelength conversion particle sintered body are moved relative to each other in a direction perpendicular to the surface so that the distance to the substrate decreases, thereby attaching the first wavelength conversion particle sintered body to the portion of the substrate to which the adhesive layer has been applied. A method for manufacturing phosphor wheels.

11. Before the step of attaching the sintered body of the first wavelength conversion particles that wavelength-converts excitation light to light of the first wavelength onto the substrate, A method for manufacturing a phosphor wheel according to claim 10, comprising the step of arranging the first guide pin at one end of the sintered body of the first wavelength conversion particles and the second guide pin at the other end of the sintered body of the first wavelength conversion particles.

12. A method for manufacturing a phosphor wheel according to claim 10 or 11, wherein in the step of forming the mixed layer type wavelength conversion layer, the portions corresponding to the first and second guide pins are removed and the mixed layer, which is a mixture of the second wavelength conversion particles and the support, is applied to the substrate in a portion adjacent to the sintered body of the first wavelength conversion particles.

13. A step of applying an adhesive layer to a substrate having an opening along a part of the circumferential direction, along the same circumferential direction as the opening, The steps include attaching a sintered body of first wavelength-converting particles that wavelength-converts excitation light to light of a first wavelength onto the substrate, The steps include curing the adhesive layer to form a sintered wavelength conversion layer, The process involves coating the substrate with a mixed layer on the same circumference as the sintered wavelength conversion layer, which is made by mixing a second wavelength conversion particle that converts the excitation light to light of a second wavelength different from the first wavelength with a support, and a support. The process involves curing the aforementioned mixed layer to form a mixed-layer type wavelength conversion layer, It has, In the step of attaching the sintered body of the first wavelength conversion particles, A step of providing alignment guide pins around the sintered body of the first wavelength conversion particle, The steps include moving the substrate and the sintered body of the first wavelength conversion particles relative to each other along the guide pins in a direction perpendicular to the surface, thereby attaching the sintered body of the first wavelength conversion particles to the portion of the substrate to which the adhesive layer has been applied, Includes, If the center angle of the sintered body of the first wavelength conversion particle is smaller than the design value, the sintered body of the first wavelength conversion particle is shifted so as to approach the center of rotation, and the end of the sintered body of the first wavelength conversion particle is positioned at the boundary between the adhesive layer and the opening, and the sintered body of the first wavelength conversion particle is attached. If the center angle of the sintered body of the first wavelength conversion particle is greater than the design value, the sintered body of the first wavelength conversion particle is shifted away from the direction of the rotation center so that the end of the sintered body of the first wavelength conversion particle is positioned at the boundary between the adhesive layer and the opening, and the sintered body of the first wavelength conversion particle is attached. A method for manufacturing phosphor wheels.

Images