Ceramic Phosphor Wheel Mechanical Fastening
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Solution Overview
Problem
Conventional phosphor-in-silicone colour wheels used in high-power laser projectors suffer from significant efficiency drop and short operational life due to thermal quenching and degradation of silicone glue at high temperatures, limiting their safe working temperature to around 150 degrees Celsius.
Innovation Solution
A light converter using a solid-state optical member, such as a ceramic phosphor, mechanically fastened to a base without adhesive, allowing for higher temperature operation up to 300 degrees Celsius and improved thermal conductivity, along with anti-reflection and high-reflection coatings for enhanced light conversion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If phosphor-in-silicone-glue colour wheel is used for high-power laser conversion, then light conversion function is achieved, but thermal quenching occurs and efficiency drops sharply above 150 degrees Celsius
Solution Approach 1:
The patent changes the material parameter from organic silicone-glue binder to inorganic ceramic matrix, enabling the light converter to maintain stable conversion efficiency at temperatures up to 300 degrees Celsius or higher, eliminating thermal quenching effects that limit conventional phosphor-in-silicone-glue wheels to 150 degrees Celsius
Solution Approach 2:
The patent uses composite ceramic materials doped with phosphor particles, creating a new composite structure where the ceramic matrix provides high-temperature stability while the phosphor particles maintain light conversion functionality, achieving both high power handling and efficiency stability
2Power
If phosphor-in-silicone-glue colour wheel operates at high temperature, then high power conversion is possible, but silicone glue degrades and burns reducing operational life
Solution Approach 1:
The patent changes the thermal stability parameter by replacing temperature-sensitive silicone-glue with temperature-resistant ceramic materials, enabling continuous operation at 300 degrees Celsius or higher without material degradation, thus dramatically extending operational life for high-power applications
Solution Approach 2:
The patent eliminates the use of consumable organic glue that requires frequent replacement due to degradation, substituting it with durable inorganic ceramic materials that maintain structural integrity and functionality over extended operational periods
3Ease of manufacture
If mechanical fastener is used to attach solid-state optical member to base, then assembly is simplified and adhesive-free high temperature operation is enabled, but assembly complexity increases
Solution Approach 1:
The patent extracts and eliminates the adhesive layer from the assembly, replacing it with direct mechanical fastening methods such as clips, clamps, or pressure-fit structures, simplifying the manufacturing process by removing curing steps while enabling adhesive-free high-temperature operation
Solution Approach 2:
The patent segments the light converter assembly into separable components (optical member and base) connected by removable mechanical fasteners, allowing independent manufacturing and assembly of components while maintaining structural integrity at high temperatures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables high-power laser projectors to maintain high luminous brightness and extended operational life by avoiding thermal quenching and degradation, with improved durability and reduced outgassing, and allows for easier assembly and cost-effective manufacturing.
Implementation Method 1
a solid-state optical member configured to absorb light of an excitation wavelength and generate light of an emission wavelength
Implementation Method 2
a mechanical fastener attaching the solid-state optical member to the base
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A light converter comprises: a solid-state optical member configured to absorb light of an excitation wavelength and generate light of an emission wavelength; a base; and a mechanical fastener attaching the solid-state optical member to the base. The light converter may be part of a light engine, a phosphor wheel or an automotive headlight. A method of manufacturing such a phosphor wheel is also provided.