Inorganic Reflective Layer for Light Conversion Element
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Solution Overview
Problem
Conventional light conversion elements using phosphors are limited by mechanical instability, thermal conductivity issues, and adverse interactions between phosphors and binders, leading to inefficiencies in heat dissipation and optical properties.
Innovation Solution
A method involving a conversion body with an inorganic reflective layer applied to its surface, using ceramic, crystal, or glass materials, which forms an adhesive connection with the conversion body, enhancing stability and efficiency by reflecting electromagnetic radiation and improving luminance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphors are used without binders, then optical and thermal properties are improved, but mechanical stability deteriorates
Solution Approach 1:
An inorganic intermediate layer is introduced between the phosphor particles and the organic binder. This intermediate layer acts as a mediator that prevents direct contact between phosphors and binder, avoiding adverse interactions while still allowing mechanical stabilization. The intermediate layer has properties that are compatible with both phosphors and binders, resolving the contradiction between maintaining optical/thermal properties and achieving mechanical stability.
2Stability of the object's composition
If binders are used to stabilize phosphor layers, then mechanical stability is improved, but optical and thermal properties deteriorate
Solution Approach 1:
The inorganic intermediate layer serves as a protective barrier that prevents the organic binder from directly interacting with phosphor particles. This eliminates adverse chemical interactions that would degrade optical and thermal properties, while still allowing the binder to provide mechanical stabilization to the phosphor layer structure.
3Temperature
If conversion elements are made thin for better heat dissipation, then thermal management is improved, but mechanical stability deteriorates
Solution Approach 1:
The phosphor layer is constructed as a composite material system consisting of phosphor particles, inorganic intermediate layer, and organic binder. This composite structure provides both the thin profile needed for heat dissipation and the mechanical stability required for structural integrity. The combination of materials with different properties creates a composite that simultaneously achieves thermal and mechanical performance.
4Strength
If silicone is used to encapsulate conversion elements, then mechanical protection is improved, but device size increases
Solution Approach 1:
The patent extracts and removes the silicone encapsulation layer from the conversion element structure. By eliminating this bulky protective layer, the device size is significantly reduced while the essential mechanical protection is maintained through the optimized phosphor layer structure with inorganic intermediate layer and binder system.
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 results in a more stable and efficient light conversion element with high luminance, capable of converting electromagnetic radiation effectively while maintaining a compact size, outperforming conventional elements in terms of efficiency and thermal management.
Implementation Method 1
forming a reflective layer that reflects the electromagnetic radiation and/or converted electromagnetic radiation with the inorganic material
Implementation Method 2
the inorganic material of the reflective layer enters into an adhesive connection with the conversion body
Implementation Method 3
phosphors are irradiated by LEDs and/or laser diodes and in turn emit light having a different wavelength
Implementation Method 4
Thermal losses that arise in the process have to be dissipated, for example, via the carrier to avoid overheating and thus thermally governed changes in the optical properties
Data Source
AI summary
A method of producing a conversion element includes providing a conversion body that converts electromagnetic radiation with regard to the wavelength thereof; applying an inorganic material to at least one portion of the conversion body; and forming a reflective layer that reflects the electromagnetic radiation and/or converted electromagnetic radiation with the inorganic material such that the inorganic material of the reflective layer enters into an adhesive connection with the conversion body.