Phosphor Wheel Manufacturing via Disk-Derived Segments
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Solution Overview
Problem
Manufacturing phosphor wheels with different outer shapes, such as ϕ50 and ϕ90, requires separate manufacturing devices, leading to high investment costs and reduced productivity due to the need for individual production lines and reduced yield when attempting to produce both shapes with the same device.
Innovation Solution
A phosphor wheel with a phosphor formed from small pieces cut from a disk shape, arranged around the axis of rotation on a substrate, allowing for the production of phosphor wheels with various outer diameters using the same manufacturing facility and steps, enhancing flexibility and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate manufacturing devices are used for phosphor wheels with different outer shapes, then manufacturing precision is maintained, but device complexity and investment costs increase
Solution Approach 1:
The patent applies universality by designing a single manufacturing device that can produce phosphor wheels with multiple different outer shapes. The device includes a molding system that can form phosphor-containing resin compositions into various shapes (e.g., φ50, φ90) using the same basic equipment, thereby eliminating the need for separate manufacturing devices for each shape while maintaining manufacturing precision.
2Manufacturing precision
If separate manufacturing devices are used for different phosphor wheel shapes, then manufacturing precision is maintained, but productivity decreases
Solution Approach 1:
The patent improves productivity by implementing a universal manufacturing device that can produce multiple phosphor wheel shapes without requiring separate production lines. The device enables switching between different shapes using the same equipment, reducing setup time and increasing overall production capacity while maintaining manufacturing precision.
Solution Approach 2:
The patent merges the manufacturing capabilities for different phosphor wheel shapes into a single integrated device. By combining the molding, heating, and cooling functions into one system that can handle multiple shapes, the patent achieves both high productivity and manufacturing precision simultaneously.
3Productivity
If phosphor wheels with different shapes are produced on the same device, then productivity increases, but manufacturing precision deteriorates
Solution Approach 1:
The patent resolves this contradiction by designing a universal device with precise control systems that can maintain manufacturing precision across multiple shapes. The device includes controlled heating and cooling mechanisms that ensure consistent quality regardless of the phosphor wheel shape being produced, thereby maintaining precision while achieving high productivity.
Solution Approach 2:
The patent uses parameter changes to adapt the manufacturing process for different shapes while maintaining precision. By adjusting parameters such as heating temperature, cooling rate, and molding pressure within controlled ranges, the device can produce various phosphor wheel shapes with consistent manufacturing precision, resolving the contradiction between productivity and precision.
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 approach enhances productivity and yield by allowing the production of phosphor wheels with different outer shapes using the same manufacturing facility, reducing inventory issues and enabling flexible production planning.
Implementation Method 1
The phosphor on the phosphor wheel is irradiated with excitation light such as blue light, and generated green fluorescence and yellow fluorescence are used as illumination light
Data Source
AI summary
A phosphor wheel is obtained by providing a phosphor on a rotatable substrate. The phosphor is formed of a plurality of small pieces, and the small pieces are arranged such that the phosphor has a ring shape, or a shape obtained by cutting away a portion from a ring shape about an axis of rotation of the substrate.