Phosphor Wheel Segmentation for Efficiency and Cost Balance

Solution Overview

Problem

Conventional phosphor wheels face challenges in achieving a balance between conversion efficiency, heat resistance, and cost, with mixed layer type wavelength conversion layers being cost-effective but inefficient, and sintered body type layers being efficient and heat-resistant but costly.

Innovation Solution

A phosphor wheel design incorporating both sintered body type and mixed layer type wavelength conversion layers, with a rotatable substrate and an adhesive layer between the substrate and the wavelength conversion layers, allowing for optimal balance in performance and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a mixed layer type wavelength conversion layer is used, then cost is reduced, but conversion efficiency and heat resistance deteriorate

Engineering Contradiction:

ImprovecostVSAvoidconversion efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The wavelength conversion layer is divided into multiple regions with different structures: a first region uses sintered body type particles for high conversion efficiency, while a second region uses mixed layer type structure for cost effectiveness. This segmentation allows each region to optimize for its specific function, resolving the contradiction between cost and performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the wavelength conversion layer are assigned different material compositions and structures based on local requirements. The first region near the excitation light source uses sintered body particles for optimal conversion, while the second region uses mixed layer structure, creating local quality variations that balance overall system performance and cost.

Inventive Principle:

Principle #3Local quality

2Reliability

If a sintered body type wavelength conversion layer is used, then conversion efficiency and heat resistance are improved, but cost increases

Engineering Contradiction:

Improveconversion efficiencyVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The wavelength conversion layer is divided into multiple regions with different structures: a first region uses sintered body type particles for high conversion efficiency, while a second region uses mixed layer type structure for cost effectiveness. This segmentation allows each region to optimize for its specific function, resolving the contradiction between cost and performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the wavelength conversion layer are assigned different material compositions and structures based on local requirements. The first region near the excitation light source uses sintered body particles for optimal conversion, while the second region uses mixed layer structure, creating local quality variations that balance overall system performance and cost.

Inventive Principle:

Principle #3Local quality

3Temperature

If a sintered body type wavelength conversion layer is used, then heat resistance is improved, but cost increases

Engineering Contradiction:

Improveheat resistanceVSAvoidcost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The wavelength conversion layer is divided into multiple regions with different structures: a first region uses sintered body type particles for high conversion efficiency, while a second region uses mixed layer type structure for cost effectiveness. This segmentation allows each region to optimize for its specific function, resolving the contradiction between cost and performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the wavelength conversion layer are assigned different material compositions and structures based on local requirements. The first region near the excitation light source uses sintered body particles for optimal conversion, while the second region uses mixed layer structure, creating local quality variations that balance overall system performance and cost.

Inventive Principle:

Principle #3Local quality

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 phosphor wheel achieves an excellent balance between conversion efficiency, heat resistance, and cost, addressing the limitations of conventional designs by combining the strengths of sintered body and mixed layer type wavelength conversion layers.

Implementation Method 1

a sintered body of first wavelength conversion particles that wavelength-convert excitation light into light of a first wavelength

Methodology Applied

Scientific EffectWavelength conversion: Fluorescence

Implementation Method 2

second wavelength conversion particles that wavelength-convert the excitation light into light of a second wavelength

Methodology Applied

Scientific EffectWavelength conversion: Fluorescence

Data Source

PatentUS20250189780A1Phosphor wheel, light source device, projection type image display device, and method for producing phosphor wheel

Publication Date: 2025.06.12 PANASONIC PROJECTOR & DISPLAY CORPORATION

AI summary

A phosphor wheel comprises a rotatable substrate, a plurality of wavelength conversion layers, and an adhesive layer disposed between the substrate and the plurality of wavelength conversion layers. At least a first wavelength conversion layer among the plurality of wavelength conversion layers is a sintered body type wavelength conversion layer made of a sintered body of first wavelength conversion particles that wavelength-convert excitation light into light of a first wavelength. At least a second wavelength conversion layer among the plurality of wavelength conversion layers is a mixed layer type wavelength conversion layer that is a mixed layer of a support and second wavelength conversion particles filled in the support that wavelength-convert the excitation light into light of a second wavelength different from the first wavelength.