Fluorescent Member Sintering for Reliable Fixation
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Solution Overview
Problem
The manufacturing of fluorescent-material-containing members is cumbersome and lacks reproducibility due to the need for precise shaping and securing of wavelength conversion members within holders, involving complex steps like forming through holes and applying adhesives.
Innovation Solution
A method involving the use of powdered light-reflective and fluorescent materials, where the powder is sintered to form an integral sintered body with the fluorescent member, allowing for easier integration and removal to create a member with improved reproducibility and reduced complexity in manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic wavelength conversion member is secured to a through hole of holder with adhesive, then the fluorescent member can be fixed in position, but the manufacturing process becomes cumbersome and reproducibility is difficult to achieve
Solution Approach 1:
The patent merges the fluorescent member and light-reflective member into a single integral sintered body formed from mixed powders. This eliminates the need for separate adhesive bonding steps and through-hole formation, resolving the contradiction by combining multiple manufacturing operations into one sintering process while maintaining reliable fixation through integral structure
Solution Approach 2:
The sintered body simultaneously provides both fluorescent conversion function and light reflection function through the integrated structure. The light-reflective member forms both the reflective surface and the structural support, eliminating the need for separate holder and adhesive components, thus simplifying the manufacturing process while maintaining reliability
2Manufacturing precision
If the shape of the wavelength conversion member is required to fit the shape of the through hole in the holder, then precise positioning is achieved, but manufacturing with good reproducibility becomes difficult
Solution Approach 1:
The patent combines the fluorescent member and light-reflective member into a single sintered body formed from mixed powders. This integral structure inherently provides precise positioning without requiring the fluorescent member to fit into a pre-formed through hole, as both components are formed together in their final positions during sintering, thereby improving manufacturing reproducibility
Solution Approach 2:
The patent performs preliminary mixing of powders and preliminary forming of the green body before sintering. This preliminary action establishes the precise spatial relationship between fluorescent and light-reflective materials in the green state, which is then permanently fixed during sintering, achieving both positioning precision and manufacturing reproducibility
3Ease of manufacture
If multiple steps including forming through holes, shaping wavelength conversion member, and securing with adhesive are used, then assembly is achieved, but the manufacturing process becomes time-consuming and complex
Solution Approach 1:
The patent merges forming, positioning, and fixing operations into a single sintering process. The fluorescent member and light-reflective member are formed and fixed together in one step without requiring separate through-hole formation, shaping, and adhesive bonding operations, dramatically reducing manufacturing time and complexity while maintaining ease of manufacture
Solution Approach 2:
The patent segments the manufacturing process into two main stages: (1) powder preparation and green body formation, and (2) sintering. This segmentation allows complex integral structures to be formed through a relatively simple two-stage process, reducing overall manufacturing time and complexity compared to multiple separate assembly steps
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 method simplifies the manufacturing process by eliminating the need for precise shaping and adhesives, enhancing reproducibility and enabling efficient heat transfer while maintaining high light reflectance and transmissivity.
Implementation Method 1
obtaining a sintered body by sintering the powder of the light-reflective member, the sintered body including the light-reflective member integrally formed with the fluorescent member
Implementation Method 2
providing a fluorescent member including a fluorescent material
Data Source
AI summary
A method of manufacturing a fluorescent-material-containing member includes: providing a fluorescent member including a fluorescent material, the fluorescent member having a first main surface side including a plurality of projections; disposing a powder of a light-reflective member between the projections of the fluorescent member; obtaining a sintered body by sintering the powder of the light-reflective member, and removing part of the sintered body from at least one of a first main surface side and a second main surface side of the fluorescent member to obtain the fluorescent-material-containing member including a first surface arranged on the first main surface side has and defined by the fluorescent member and the light-reflective member, and a second surface arranged on the second main surface side has and defined by the fluorescent member and the light-reflective member or defined solely by the fluorescent member.