Modular Wavelength Conversion Device Ceramic Substrates
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Solution Overview
Problem
Existing wavelength conversion devices using mirror-surface metal substrates face challenges in high temperature stability, complex fabrication processes, and long production cycles due to the difficulty of coating and sintering multiple phosphor layers of different colors on large substrates.
Innovation Solution
The use of ceramic substrates and a modular design with diffuse reflection and wavelength conversion layers formed by sintering slurry materials, allowing for separate optimization of each module's processing conditions and reducing the complexity of the fabrication process by using different glass powders with varying softening points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mirror-surface metal substrates are used for wavelength conversion devices, then high reflectivity is achieved, but thermal stability deteriorates at high temperatures
Solution Approach 1:
The patent uses a composite structure consisting of a metal substrate with a ceramic coating layer. The metal substrate provides high reflectivity while the ceramic coating layer provides thermal stability and resistance to high temperatures, thus combining the advantages of both materials to resolve the contradiction between reflectivity and thermal stability.
2Adaptability or versatility
If multiple phosphor layers of different colors are coated on large substrates, then multi-color wavelength conversion is achieved, but fabrication complexity increases
Solution Approach 1:
The patent divides the wavelength conversion device into multiple independent segments or modules, each containing a specific phosphor layer for a particular color conversion. This segmentation allows each module to be fabricated separately with optimized processing conditions for that specific phosphor, then assembled into a complete multi-color device, thereby reducing the complexity of fabricating all phosphor layers simultaneously on a single large substrate.
3Quantity of substance
If multiple passes of blade coating and sintering are performed for different phosphor layers, then multi-color phosphor deposition is achieved, but production cycle lengthens
Solution Approach 1:
The patent prepares phosphor slurries with optimized formulations in advance, including pre-mixed phosphor particles, binders, and solvents in precise ratios. This preliminary preparation allows the slurries to be applied directly to substrates without requiring multiple adjustment and re-coating passes, enabling more efficient single-pass or reduced-pass coating and sintering processes that deposit complete functional phosphor layers, thus shortening the production cycle while achieving full phosphor coverage.
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 approach enhances thermal stability, reduces production time, and allows for flexible and high-quality wavelength conversion devices with improved thermal management and cost-effectiveness by enabling separate processing of each phosphor layer under optimal conditions.
Implementation Method 1
The reflective layer is a diffuse reflection layer, formed by sintering a diffusing material slurry which includes white scattering particles
Implementation Method 2
formed by sintering a diffusing material slurry which includes white scattering particles, a first glass powder and an organic carrier
Implementation Method 3
wavelength conversion layer, which are sequentially stacked together forming an integral unit
Data Source
Figure 1~2
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AI summary
Disclosed is a manufacturing method for a wavelength conversion device, comprising: preparing a plurality of wavelength conversion modules (2a, 2b, 2c), each wavelength conversion module (2a, 2b, 2c) comprising a ceramic substrate (23), a reflecting layer (22) and a fluorescent powder layer (21), said layers being stacked sequentially and formed into one piece; installing and fixing the plurality of wavelength conversion modules (2a, 2b, 2c) on one surface of a base substrate. By arranging different fluorescent powders respectively on the different wavelength conversion modules (2a, 2b, 2c), a plurality of wavelength conversion modules (2a, 2b, 2c) can be produced separately at the same time, thereby significantly shortening the production cycle. Each such module is produced independently and is thus not subject to the restrictions of the characteristics of other fluorescent powders. This is beneficial for the optimization of the various processes, and a wavelength conversion device having optimal performance is thereby obtained.