Phosphor Layer Reflection Stack for Adhesion and Heat Dissipation
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Solution Overview
Problem
The reliability of the substrate supporting the reflection and phosphor layers in wavelength conversion elements is limited.
Innovation Solution
A phosphor device with a substrate, a phosphor layer containing pores, a first reflection layer with a multilayer structure of high- and low-refractive layers, a joint layer containing a first metal, and a metal layer with a higher melting point than the first metal, enhancing adhesiveness and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple reflection layer structure is used, then device complexity is reduced, but reliability and adhesion between layers deteriorate
Solution Approach 1:
The reflection layer is segmented into multiple functional layers: a first reflection layer for optical reflection, a joint layer for adhesion, and a metal layer for thermal management. This segmentation allows each layer to specialize in its function, improving overall reliability without requiring excessive structural complexity
Solution Approach 2:
The device uses composite material structures where the joint layer combines a first metal with good adhesion properties, and the metal layer uses a second metal with high melting point for thermal stability. This composite approach resolves the contradiction by combining materials with different properties to achieve both simplicity and reliability
2Ease of manufacture
If a single-layer metal structure is used, then manufacturing is simplified, but heat dissipation capability deteriorates
Solution Approach 1:
The metal structure is divided into two layers with distinct functions: the joint layer for adhesion and the metal layer for heat dissipation. This segmentation enables optimized thermal management while maintaining manufacturing feasibility through standardized layer deposition processes
Solution Approach 2:
Different regions of the metal structure have different properties: the joint layer has high adhesion quality for bonding, while the metal layer has high thermal conductivity for heat dissipation. This local quality differentiation resolves the contradiction by optimizing each region for its specific function
3Use of energy by moving object
If high-refractive-index materials are used throughout, then light reflection efficiency is improved, but light transmission and conversion efficiency deteriorate
Solution Approach 1:
The optical layers have spatially varying refractive indices: the first reflection layer uses high-refractive-index materials for efficient light reflection, while the phosphor layer uses low-refractive-index materials to minimize light scattering and maximize light transmission. This local quality optimization resolves the contradiction by matching material properties to functional requirements at each location
Solution Approach 2:
The refractive index parameter is changed across different layers to optimize performance: high refractive index in the reflection layer for reflection efficiency, and low refractive index in the phosphor layer for light transmission. This parameter variation resolves the contradiction by adapting optical properties to local functional demands
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 configuration results in a highly reliable phosphor device with improved adhesiveness, reduced peeling, and efficient heat dissipation, maintaining high light conversion efficiency and stability over time.
Implementation Method 1
The first reflection layer has a multilayer structure in which high-refractive layers and low-refractive layers are alternately stacked, the low-refractive layer having a refractive index smaller than a refractive index of the high-refractive layer
Implementation Method 2
a wavelength conversion element which contains phosphor that emits fluorescence upon receipt of laser light emitted from a laser source
Implementation Method 3
a metal layer between the first reflection layer and the joint layer, the metal layer containing a second metal having a melting point higher than a melting point of the first metal
Data Source
AI summary
A phosphor device includes: a substrate; a phosphor layer including pores; a reflection layer between the substrate and the phosphor layer; a joint layer between the substrate and the reflection layer, the joint layer containing a first metal; and a metal layer between the reflection layer and the joint layer, the metal layer containing a second metal having a melting point higher than a melting point of the first metal. The reflection layer has a multilayer structure obtained by alternately stacking a high-refractive layer and a low-refractive layer having a refractive index smaller than a refractive index of the high-refractive layer.