Fluorinated Garnet Phosphor for Heat-Resistant Projection Wheels
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Solution Overview
Problem
Current phosphor wheels in projection devices using laser diodes face issues with high-temperature degradation due to low thermal conductivity and lattice defects, leading to reduced light emitting efficiency and reliability.
Innovation Solution
A wavelength conversion material with a garnet crystal structure containing fluorine ions to replace oxygen ions, reducing lattice defects and increasing thermal conductivity, combined with a manufacturing method that lowers sintering temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If silicone is used to mix with phosphor to form the phosphor wheel, then the phosphor wheel can be manufactured, but thermal conductivity is low and high-temperature resistance is poor, leading to degradation or burning under laser excitation
Solution Approach 1:
The patent changes the material composition parameters by replacing silicone with glass frit, which fundamentally alters the thermal properties of the phosphor wheel matrix, enabling it to withstand high temperatures without degradation
Solution Approach 2:
The patent creates a composite material system combining glass frit with phosphor particles, where the glass frit matrix provides high-temperature stability and thermal conductivity while the phosphor particles maintain the wavelength conversion function
2Reliability
If glass frit is used to replace silicone and mix with phosphor, then thermal conductivity and light transmittance are improved, but phosphor conversion efficiency is insufficient due to lattice defects of oxygen, requiring high sintering temperature
Solution Approach 1:
The patent modifies the chemical composition parameters of the phosphor material by introducing fluorine elements (CaF2, SrF2, BaF2) into the phosphor lattice structure, which changes the lattice dynamics and reduces oxygen vacancy defects, thereby improving phosphor conversion efficiency
Solution Approach 2:
The patent uses fluorine-containing compounds as intermediary substances that facilitate the formation of a more efficient phosphor lattice structure during sintering, acting as a mediator between the glass frit matrix and phosphor particles to enhance overall conversion efficiency
3Reliability
If high sintering temperature is used to form phosphor with glass frit, then thermal conductivity is improved, but operability is poor due to difficulty in manufacturing
Solution Approach 1:
The patent changes the sintering temperature parameter by introducing fluorine-containing compounds that lower the sintering temperature requirement, making the manufacturing process more controllable and easier to operate while maintaining thermal conductivity
Solution Approach 2:
The fluorine-containing compounds act as sintering aids that mediate the high-temperature sintering process, enabling it to proceed at lower temperatures with better control, thus improving operability while maintaining the desired thermal properties
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 enhances phosphor conversion efficiency by 5-7% and improves thermal conductivity, resulting in higher optical quality for projection devices.
Implementation Method 1
A wavelength conversion material with a garnet crystal structure containing fluorine ions to replace oxygen ions, reducing lattice defects and increasing thermal conductivity
Implementation Method 2
a technique of using laser light sources to excite phosphor to generate pure color light sources required by projectors
Implementation Method 3
The manufacturing method of the wavelength conversion material includes sintering a precursor composition
Data Source
AI summary
A wavelength conversion material and a manufacturing method thereof, a wavelength conversion device, and a projection device are provided. The wavelength conversion material has higher phosphor conversion efficiency. The wavelength conversion material includes a first phase. A composition of the first phase is M3Al5(O1-0.5xFx)12:Ce3+, where M is at least one selected from a group consisting of yttrium (Y), lutetium (Lu), gadolinium (Gd), terbium (Tb), praseodymium (Pr), and neodymium (Nd), and 0.012≤x≤0.3. The wavelength conversion material with good phosphor conversion efficiency is provided.