Microstructured Phosphor Layer for Laser Projector Thermal Management
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Solution Overview
Problem
The increased energy density of the excitation beam in projector phosphor layers leads to elevated temperatures, reduced conversion efficiency, and potential damage such as burning or cracking, compromising the reliability and optical performance of projection apparatuses.
Innovation Solution
A light wavelength conversion element with a substrate featuring microstructures on its surface, where the light wavelength conversion substance covers these microstructures, and the energy density distribution of the excitation beam is optimized to align with the microstructure positions, reducing peak energy density and preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the number of excitation light sources is increased or high efficiency excitation light sources are used, then the brightness of the laser projector is improved, but the energy density of the excitation beam borne by the phosphor layer is significantly increased
Solution Approach 1:
The patent applies local quality by creating microstructures (protrusions or recesses) at specific locations on the phosphor layer where the excitation beam energy density is highest. These localized structural modifications enable differential heat management - the microstructures act as heat dissipation channels or reflectors specifically at the hottest spots, while leaving other regions unchanged. This resolves the contradiction by locally addressing the temperature problem without reducing overall brightness.
2Illumination intensity
If the energy density of the excitation beam is increased, then the brightness is improved, but the phosphor layer is likely to be burned or cracked, which leads to poor reliability
Solution Approach 1:
The patent implements beforehand cushioning by pre-configuring microstructures (protrusions or recesses) on the phosphor layer before operation. These microstructures serve as preventive heat management features that cushion the phosphor layer against excessive energy density accumulation. By having these protective structures in place beforehand, the system prevents burning or cracking before they can occur, thereby maintaining reliability while allowing high brightness operation.
3Illumination intensity
If the energy density of the excitation beam is increased, then the brightness is improved, but the conversion efficiency of the phosphor layer is attenuated due to heat
Solution Approach 1:
The patent applies local quality by creating microstructures (protrusions or recesses) at specific locations on the phosphor layer where the excitation beam energy density is highest. These localized structural modifications enable differential heat management - the microstructures act as heat dissipation channels or reflectors specifically at the hottest spots, while leaving other regions unchanged. This resolves the contradiction by locally addressing the temperature problem without reducing overall brightness.
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 configuration enhances the reliability and optical efficiency of the projection apparatus by maintaining lower energy density on the phosphor layer, reducing the risk of damage and maintaining high conversion efficiency.
Implementation Method 1
When the excitation beam is transmitted to the light wavelength conversion substance, the light wavelength conversion substance is excited by the excitation beam and emits a conversion beam
Data Source
AI summary
A light wavelength conversion element is configured to receive an excitation beam from a light incident side, comprising a substrate and a light wavelength conversion substance. The substrate has a surface facing the light incident side. The surface has at least one microstructure protruded toward the light incident side. The light wavelength conversion substance is disposed on the surface and covers the at least one microstructure. The light wavelength conversion substance is excited by the excitation beam and emits a conversion beam. The excitation beam forms an exciting light spot on the light wavelength conversion substance. The energy density distribution of the exciting light spot has at least one peak value. A position corresponding to the at least one peak value on the light wavelength conversion substance corresponds to a position of the at least one microstructure. Additionally, a projection apparatus is provided.