Phosphor Layer Bonding for Thermal Conductivity and Adhesion
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Solution Overview
Problem
Phosphors emitting high-brightness light under high energy density excitation tend to have high temperatures, which can lower quantum efficiency, and existing solutions with inorganic binders for thermal conductivity suffer from poor adhesion and toughness.
Innovation Solution
An optical element with a phosphor layer and a bonding layer, where the phosphor layer contains an inorganic binder and phosphor particles, and the bonding layer is made of an organic binder, ensuring intimate contact and improved durability while maintaining adhesion to a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an inorganic binder is used in the phosphor layer, then thermal conductivity is improved, but adhesion to substrate and toughness deteriorate
Solution Approach 1:
The patent uses a composite binder system comprising both inorganic binder (for thermal conductivity) and organic binder (for adhesion and toughness). This composite approach allows the phosphor layer to simultaneously achieve high heat dissipation capability through the inorganic component and strong substrate bonding through the organic component, resolving the contradiction between thermal management and mechanical reliability
2Temperature
If an inorganic binder is used in the phosphor layer, then thermal conductivity is improved, but toughness deteriorates
Solution Approach 1:
The organic binder component in the composite binder system provides toughness and flexibility to the phosphor layer, compensating for the brittleness inherent in inorganic binders. This allows the layer to withstand mechanical stresses and shocks while maintaining the high thermal conductivity needed for heat dissipation
3Illumination intensity
If phosphor emits high-brightness light under high energy density excitation, then luminous efficiency is improved, but temperature increases lowering quantum efficiency
Solution Approach 1:
The patent extracts heat from the phosphor layer by incorporating a thermally conductive adhesive layer that serves as a heat sink and thermal pathway. This layer actively removes excess heat generated during high-energy excitation, preventing temperature buildup that would otherwise reduce quantum efficiency and maintain high luminous output
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 enhances durability and maintains adhesion to the substrate, preventing damage from heat and improving luminous efficiency by effectively managing thermal conductivity and adhesion.
Implementation Method 1
a phosphor layer facing a lower layer, and a bonding layer keeping the phosphor layer in intimate contact with the lower layer. The phosphor layer includes an inorganic binder, and phosphor particles dispersed within the inorganic binder
Implementation Method 2
a phosphor that has undergone irradiation with excitation light, such as blue laser light, radiates fluorescence
Data Source
AI summary
Provided is compatibility between adhesion to a substrate (lower layer) and durability improvement. An optical element includes a phosphor layer facing a lower layer, and a bonding layer keeping the phosphor layer in intimate contact with the lower layer. The phosphor layer includes an inorganic binder, and phosphor particle dispersed with the inorganic binder. The bonding layer includes an organic binder. The phosphor layer has a first surface facing the lower layer, a second surface opposite to the first surface, and a side surface connecting the first and second surfaces together. The bonding layer connects together the second surface, the side surface, and a surface of the lower layer to keep the phosphor layer in intimate contact with the lower layer.