Phosphor Module Heat Dissipation and Yellow Ring Reduction
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Solution Overview
Problem
Conventional phosphor modules for laser light sources experience thermal quenching and generate a yellow ring due to inefficient heat dissipation and light scattering, particularly when using ceramic phosphors with high sintering temperatures, which reduces optical conversion efficiency and brightness.
Innovation Solution
A phosphor module design incorporating a heat radiator, a phosphor layer, a reflective layer, and an adhesive layer with high thermal conductivity, where the reflective layer reflects yellow light back to the front surface and the adhesive layer enhances heat transfer, minimizing the yellow ring and increasing brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a phosphor layer is used for optical conversion of laser light, then white light can be generated, but thermal quenching occurs and optical conversion efficiency decreases due to high temperature rise
Solution Approach 1:
The patent extracts the harmful heat from the phosphor layer by introducing a heat radiator with high thermal conductivity material (thermal conductivity ≥10 W/m·K) that is in direct contact with the phosphor layer. This heat radiator extracts heat from the phosphor layer during optical conversion, preventing thermal quenching and maintaining high optical conversion efficiency while enabling sustained high brightness output.
2Illumination intensity
If the phosphor layer area is increased to improve brightness, then more light can be emitted, but yellow light scattering increases and a yellow ring is generated at the periphery
Solution Approach 1:
The patent converts the harmful yellow light that would otherwise scatter and form a yellow ring into a beneficial component by introducing a reflective layer. This reflective layer reflects the yellow light back toward the optical axis, converting the harmful peripheral scattering into useful light that contributes to the overall brightness while eliminating the yellow ring defect.
Solution Approach 2:
The patent applies different functional properties to different regions: the central region uses the phosphor layer for optical conversion, while the peripheral region uses the reflective layer to redirect scattered yellow light. This local differentiation of functional properties ensures that each region optimizes its specific function - the phosphor layer generates light efficiently while the reflective layer recovers scattered light, together eliminating the yellow ring while maintaining high brightness.
3Ease of manufacture
If conventional adhesive materials are used to bond the phosphor layer, then assembly is simple, but heat dissipation efficiency is insufficient due to low thermal conductivity
Solution Approach 1:
The patent uses a composite adhesive layer that combines the bonding function with high thermal conductivity. The adhesive layer has a thermal conductivity of ≥1 W/m·K, which is significantly higher than conventional adhesives. This composite material approach allows the adhesive to simultaneously perform both mechanical bonding and thermal conduction functions, maintaining assembly simplicity while dramatically improving heat dissipation efficiency from the phosphor layer to the heat radiator.
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 design effectively reduces the area of the yellow ring and enhances the brightness of the light source by efficiently dissipating heat and directing reflected light towards the front surface, while maintaining a controlled phosphor layer area to prevent thermal quenching.
Implementation Method 1
a phosphor layer disposed at the heat radiator and configured to absorb and emit light, where a wavelength of the emitted light is different from a wavelength of the absorbed light
Implementation Method 2
a reflective layer that covers a side surface of the phosphor layer and is configured to reflect light
Implementation Method 3
an adhesive layer disposed between the phosphor layer and the heat radiator and between the reflective layer and the heat radiator, the adhesive layer being configured to couple each of the phosphor layer and the reflective layer to the heat radiator. A thermal conductivity of the adhesive layer is greater than a thermal conductivity of each of the phosphor layer and the reflective layer
Implementation Method 4
Another object of the present disclosure may be to provide a structure for effectively releasing heat generated during optical conversion in a phosphor module to the outside
Data Source
AI summary
A phosphor module for a laser light source includes a heat radiator, a phosphor layer disposed at the heat radiator and configured to absorb and emit light, where a wavelength of the emitted light is different from a wavelength of the absorbed light, a reflective layer that covers a side surface of the phosphor layer and is configured to reflect light, and an adhesive layer disposed between the phosphor layer and the heat radiator and between the reflective layer and the heat radiator, the adhesive layer being configured to couple each of the phosphor layer and the reflective layer to the heat radiator. A thermal conductivity of the adhesive layer is greater than a thermal conductivity of each of the phosphor layer and the reflective layer.