Laser-Sintered Wavelength Conversion Layer for Heat-Resistant Optics

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Solution Overview

Problem

Current wavelength conversion layers, particularly those using organic glue, have poor thermal resistance and light transmittance, and the static pressing process for inorganic glue-based phosphor in ceramics is complex and costly.

Innovation Solution

A sol-gel method is used to form a wavelength conversion layer on a substrate, where a colloidal material and fluorescent material are mixed, and then solidified using laser sintering, eliminating the need for additional adhesives and simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If organic glue is used to produce wavelength conversion layer, then the manufacturing process is simple, but the thermal resistance and thermal conductivity are poor

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidthermal resistance

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent changes the material composition parameters by using inorganic glue (such as glass or ceramic materials) instead of organic glue to achieve high thermal resistance and thermal conductivity while maintaining manufacturing feasibility through processes like screen printing or inkjet printing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite wavelength conversion layer by combining fluorescent particles with inorganic glue materials, achieving both good thermal properties and wavelength conversion functionality in a single integrated layer

Inventive Principle:

Principle #40Composite materials

2Temperature

If static pressing process is used for phosphor in ceramic, then the thermal conductivity is high, but the manufacturing cost and complexity increase

Engineering Contradiction:

Improvethermal conductivityVSAvoidmanufacturing process complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the complex static pressing process from the manufacturing flow by using alternative deposition methods such as screen printing or inkjet printing followed by sintering, achieving similar or better thermal conductivity without the need for high-pressure pressing equipment and complex process control

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical static pressing system with a thermal sintering process, where pressureless sintering or low-pressure sintering is used to densify the ceramic matrix and achieve high thermal conductivity without complex mechanical pressing equipment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If phosphor in ceramic is sintered by static pressing process, then the thermal resistance is low, but an anti-reflection layer must be subsequently plated increasing the manufacturing cost

Engineering Contradiction:

Improvethermal resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent merges the wavelength conversion layer and the anti-reflection function into a single integrated layer by designing the ceramic matrix composition and surface properties to inherently provide both thermal management and optical anti-reflection characteristics, eliminating the need for separate anti-reflection layer deposition

Inventive Principle:

Principle #5Merging (Combining)

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 reduces manufacturing costs, increases light conversion efficiency, and enhances anti-reflection capabilities without requiring additional anti-reflection layers, while maintaining high thermal resistance and light transmittance.

Implementation Method 1

The step of solidifying the wavelength conversion material layer includes irradiating the wavelength conversion material layer with a laser

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

The first colloidal material in the wavelength conversion material layer may be melted by laser sintering to bond the fluorescent material and the substrate

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

The wavelength conversion material layer includes a first colloidal material, and a fluorescent material

Methodology Applied

Scientific EffectFluorescence: Fluorescence

Data Source

PatentUS11757071B2Wavelength conversion device and manufacturing method thereof

Publication Date: 2023.09.12 CORETRONIC CORPORATION

AI summary

A manufacturing method of a wavelength conversion device, and a wavelength conversion device manufactured by the method are provided. The manufacturing method of the wavelength conversion device of the disclosure includes the following steps. A wavelength conversion material layer is formed on a substrate by a sol-gel method. The wavelength conversion material layer includes a first colloidal material, and a fluorescent material. The wavelength conversion material layer is solidified, thereby forming a wavelength conversion layer including a plurality of first microstructures. The step of solidifying the wavelength conversion material layer includes irradiating the wavelength conversion material layer with a laser. The manufacturing method of the wavelength conversion device and the wavelength conversion device provided by the disclosure have advantages such as a simple process, and low manufacturing cost.