Opposite-Surface Phosphor Layers for Thermal Management
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Solution Overview
Problem
Existing light source apparatuses for projectors, which use multiple phosphor layers for wavelength conversion, suffer from inadequate heat dissipation, leading to decreased wavelength conversion efficiency and unstable color gamut output due to phosphor layers being layered on a single substrate surface.
Innovation Solution
The wavelength conversion element is designed with the first and second phosphor layers facing opposite surfaces of a substrate, allowing for improved heat transfer and maintaining high wavelength conversion efficiency by ensuring each phosphor layer is in direct contact with the substrate, thereby stabilizing the color gamut output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple phosphor layers are layered on one surface of a substrate, then the device complexity is reduced, but the heat dissipation becomes insufficient leading to decreased wavelength conversion efficiency
Solution Approach 1:
The patent transitions from a two-dimensional arrangement (multiple phosphor layers on one surface) to a three-dimensional arrangement (phosphor layers on opposite surfaces of the substrate). This spatial reconfiguration enables each phosphor layer to have direct thermal contact with the substrate, significantly improving heat dissipation and maintaining wavelength conversion efficiency while preserving structural compactness.
2Ease of manufacture
If multiple phosphor layers are layered on one surface of a substrate, then the manufacturing process is simplified, but the color gamut stability deteriorates due to heat accumulation
Solution Approach 1:
By distributing phosphor layers on opposite surfaces of the substrate rather than stacking them on one surface, the patent achieves better thermal management. This prevents heat accumulation that would otherwise cause wavelength shifts and color gamut instability, while the overall manufacturing process remains relatively simple and scalable.
3Loss of energy
If phosphor layers are placed on opposite surfaces of a substrate, then the heat dissipation is improved, but the device complexity increases
Solution Approach 1:
The patent segments the phosphor layer arrangement by placing different phosphor layers on opposite surfaces of the substrate rather than stacking them together. This segmentation allows each phosphor layer to independently contact the substrate for heat dissipation, improving thermal management while the substrate itself serves as the integrating structure, thereby limiting the increase in overall device complexity.
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 stability of the color gamut output by effectively dissipating heat generated in each phosphor layer, preventing a decrease in wavelength conversion efficiency and ensuring consistent light emission with a desired color tone.
Implementation Method 1
a first wavelength conversion layer that has a first light incident surface on which excitation light that belongs to a first wavelength band is incident and a first light exiting surface facing away from the first light incident surface and emits first fluorescence that belongs to a second wavelength band different from the first wavelength band
Implementation Method 2
a second wavelength conversion layer that has a second light incident surface on which at least the first fluorescence is incident and emits second fluorescence that belongs to a third wavelength band different from the first and second wavelength bands
Implementation Method 3
a substrate that has a first surface and a second surface facing away from the first surface and includes a light transmitting portion that transmits at least the first fluorescence
Data Source
AI summary
A wavelength conversion element according to an aspect of the invention includes a first wavelength conversion layer that has a first light incident surface on which excitation light is incident and a first light exiting surface facing away from the first light incident surface and emits first fluorescence, a second wavelength conversion layer that has a second light incident surface on which at least the first fluorescence is incident and emits second fluorescence, and a substrate that has a first surface and a second surface facing away from the first surface and includes a light transmitting portion that transmits at least the first fluorescence. The first wavelength conversion layer is so provided that the first light exiting surface faces the first surface of the substrate, and the second wavelength conversion layer is so provided that the second light incident surface faces the second surface of the substrate.