Ceramic Wavelength-Conversion Plate Side Emission Control
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Solution Overview
Problem
Existing wavelength-conversion plates in LED light sources face issues with side emission and thermal management, particularly in high brightness/power applications, due to the use of ceramic in silicone materials, which can lead to reduced efficacy and overheating.
Innovation Solution
The use of ceramic wavelength-conversion plates with a ceramic reflecting material eliminates the need for silicone, providing improved thermal conductivity and heat management, while maintaining high reflectance and optical efficiency by using a ceramic reflector that abuts the converter over a significant interface, enhancing light confinement and reducing side emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If ceramic in silicone materials are used to address side emission, then side emission is reduced, but thermal management deteriorates due to low thermal conductivity and potential thermal breakdown
Solution Approach 1:
The patent removes the silicone binder material from the ceramic in silicone composite, extracting the problematic organic component that causes poor thermal management. The invention uses pure ceramic or inorganic materials for both the wavelength conversion layer and the side wall reflecting layer, eliminating the thermal management issues associated with silicone while maintaining the side emission control functionality.
Solution Approach 2:
The patent changes the material composition parameter from organic-containing (ceramic in silicone) to purely inorganic (ceramic or glass ceramic materials). This parameter change fundamentally improves thermal conductivity and temperature resistance, allowing the system to operate at higher temperatures without thermal breakdown while maintaining optical performance.
2Object-generated harmful factors
If ceramic in silicone layers are cast around the wavelength-conversion plate, then side emission is controlled, but manufacturing complexity increases and filling precision becomes difficult to control
Solution Approach 1:
The patent combines the wavelength conversion function and the side wall reflecting function into a single integrated ceramic structure. The side wall reflecting layer is formed as an integral part of the wavelength conversion plate through co-sintering, eliminating the need for separate casting operations and reducing manufacturing complexity while maintaining effective side emission control.
Solution Approach 2:
The patent uses composite ceramic materials that integrate multiple functions within a single material system. The side wall reflecting layer and wavelength conversion layer are both ceramic materials that can be co-sintered together, creating a unified structure that performs both wavelength conversion and side emission control without requiring complex multi-material assembly processes.
3Object-generated harmful factors
If ceramic in silicone material is used, then side emission is addressed, but light output may be reduced due to overfilling covering the top surface
Solution Approach 1:
The patent removes the silicone binder that causes overfilling issues during casting. Without the viscous silicone material, the ceramic particles can be precisely positioned and sintered to form exact dimensional structures, preventing overfilling that would cover the light-emitting top surface while still providing complete side emission control.
Solution Approach 2:
The patent employs hydraulic pressing during the sintering process to precisely control the density and dimensions of the ceramic structure. This hydraulic pressure ensures complete filling of the mold cavity with ceramic material without overfilling, achieving precise dimensional control that protects the top light-emitting surface while maintaining effective side wall reflection.
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
This solution enables efficient light conversion with reduced side emission and improved thermal management, suitable for high brightness/power applications, and allows for the production of wavelength-conversion plates with tailored optical properties, capable of operating at higher temperatures than conventional systems.
Implementation Method 1
Absorption of the primary light can excite the wavelength-conversion material to a higher energy state. When the wavelength-conversion material returns to a lower energy state, it emits secondary light, generally of a different wavelength/wavelength range than the primary light.
Implementation Method 2
The reflector may include a second ceramic material capable of reflecting secondary light emitted by the converter.
Data Source
AI summary
A wavelength-conversion plate is described herein. The wavelength conversion plate may include a converter of a first ceramic material and a reflector of a second ceramic material. The first ceramic material converts the primary light emitted by a light source such as a light emitting diode (LED) into a secondary light and the second ceramic material reflects the secondary light emitted by said converter. Preferably, the converter is inlaid into the reflector so that the reflector surrounds an outer edge of the converter. Such a configuration has an advantage of reducing unwanted side emissions from the converter.