Phosphor Wheel Bonding Layer with High-Conductivity Particles
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Solution Overview
Problem
Current phosphor wheels in projection image display apparatuses face challenges in achieving high fluorescent efficiency and thermal conductivity, with existing solutions relying on titanium oxide layers that have limitations in reflectance and thermal management.
Innovation Solution
A phosphor wheel design featuring a substrate with a light reflection layer, a phosphor layer, and a bonding layer that includes particles with higher thermal conductivity and reflectance than the base material, enhancing both fluorescent efficiency and thermal conductivity by optimizing the thickness and composition of the bonding layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a titanium oxide layer is used in the phosphor wheel, then the reflectance is improved, but the thermal conductivity is insufficient
Solution Approach 1:
The bonding layer uses a composite material consisting of a resin base material combined with high-thermal-conductivity particles (such as alumina or boron nitride). This composite structure allows the bonding layer to provide both optical bonding functionality and enhanced thermal conductivity, resolving the contradiction between reflectance improvement and thermal management.
Solution Approach 2:
The patent applies different material properties to different layers: the light reflection layer uses titanium oxide for high reflectance, while the bonding layer uses a composite of resin and thermal-conductive particles for both bonding and thermal management. This local differentiation of material qualities allows each layer to optimize its specific function without compromising the other.
2Stability of the object's composition
If the bonding layer thickness is increased, then the structural stability is improved, but the thermal conductivity decreases
Solution Approach 1:
The patent optimizes the thickness of the bonding layer to a specific range (5-50 μm) to achieve the best balance between structural stability and thermal conductivity. By carefully controlling this parameter, the bonding layer maintains sufficient mechanical strength while allowing adequate heat dissipation from the phosphor layer.
Solution Approach 2:
The bonding layer is formulated as a composite material with high-thermal-conductivity particles suspended in a resin matrix. This composite structure enables the bonding layer to maintain structural integrity even at optimized thicknesses while providing effective thermal conduction pathways for heat removal from the phosphor layer.
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 proposed design increases fluorescent efficiency and thermal conductivity, reducing temperature-related quenching effects and maintaining reflectance while alleviating distortion, thus improving the overall performance of the phosphor wheel.
Implementation Method 1
a light reflection layer disposed on one surface of the substrate
Implementation Method 2
the fluorescent light emitter converts a wavelength of the excitation light
Implementation Method 3
a bonding layer which is located between and bonds the light reflection layer and the phosphor layer, wherein the bonding layer contains a particle which is higher in thermal conductivity than a base material of the bonding layer
Data Source
AI summary
A phosphor wheel includes: a substrate; a light reflection layer disposed on one surface of the substrate; a phosphor layer; and a bonding layer which is located between and bonds the light reflection layer and the phosphor layer, wherein the bonding layer contains a particle which is higher in thermal conductivity than a base material of the bonding layer and higher in light reflectance than the light reflection layer.