Phosphor Wheel Partial Reflective Coating Light Convergence
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Solution Overview
Problem
Existing phosphor wheels in light source devices for projection display apparatuses face challenges in manufacturability, reliability, and light-converging efficiency due to uneven surface levels and inadequate reflective coatings, which affect the convergence and reflection of excitation and fluorescence light.
Innovation Solution
A phosphor wheel design featuring a base plate with an annular phosphor layer and a reflective coating, where the phosphor layer is sintered in a ring shape with an anti-reflection coating on one side and a thin first reflective coating on a partial area, optimized with a diffusion layer and a second reflective coating to enhance thermal conductivity and reflectance, improving light-converging efficiency and manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional phosphor wheel structure is used with base plate, phosphor layer, and reflective coating, then the basic light conversion function is achieved, but the light-converging efficiency of fluorescence light and reflected light is insufficient
Solution Approach 1:
The patent applies local quality by providing a reflective coating only on a partial area of the annular phosphor layer rather than uniformly across the entire surface. This localized reflective coating is strategically positioned to reflect specific portions of excitation light that would otherwise be wasted, thereby improving light-converging efficiency without requiring complete surface coverage, which would increase complexity and cost.
Solution Approach 2:
The patent introduces a vertical dimension to light management by creating a three-dimensional light path control system. The reflective coating on the partial area of the phosphor layer redirects light at different angles and planes, adding a vertical component to light convergence that improves overall efficiency without expanding the horizontal footprint of the device.
2Ease of manufacture
If the phosphor layer surface and reflective coating surface are at different levels, then manufacturing is simplified, but the balance and reliability of the phosphor wheel deteriorates
Solution Approach 1:
The patent achieves equipotentiality by designing the reflective coating and phosphor layer surfaces to be at substantially the same level, creating a balanced rotational mass distribution. This level alignment ensures that the phosphor wheel rotates smoothly without vibration or imbalance, thereby improving reliability and product stability while maintaining manufacturability through conventional coating processes.
3Loss of energy
If a uniform reflective coating is applied across the entire phosphor layer, then light reflection is maximized, but the complexity of the device structure increases
Solution Approach 1:
The patent applies local quality by providing a reflective coating only on a partial area of the annular phosphor layer rather than uniformly across the entire surface. This localized reflective coating is strategically positioned to reflect specific portions of excitation light that would otherwise be wasted, thereby improving light-converging efficiency without requiring complete surface coverage, which would increase complexity and cost.
4Illumination intensity
If the phosphor layer is made thicker to improve fluorescence emission, then the light-converging efficiency decreases due to increased light scattering
Solution Approach 1:
The patent introduces a vertical dimension to light management by creating a three-dimensional light path control system. The reflective coating on the partial area of the phosphor layer redirects light at different angles and planes, adding a vertical component to light convergence that improves overall efficiency without expanding the horizontal footprint of the device.
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 improved phosphor wheel design enhances light-converging efficiency, manufacturability, and reliability by ensuring uniform light convergence and reflection, leading to a more effective light source device and projection display apparatus with increased brightness and product reliability.
Implementation Method 1
The phosphor layer is formed on an opposite side of the first reflective coating from the base plate, and emits fluorescence light by excitation light from the light source
Implementation Method 2
The second reflective coating is formed on a second portion of the base plate, and reflects the light from the light source
Implementation Method 3
the phosphor layer is sintered in a ring shape
Data Source
AI summary
A phosphor wheel of a first exemplary embodiment in the present disclosure includes a base plate, an annular phosphor provided on the base plate, and a reflective coating provided on a partial area of the annular phosphor. Further, a phosphor wheel of a second exemplary embodiment includes a base plate, an annular phosphor layer that is provided on the base plate and constituted by a plurality of phosphor segments, and a reflective coating provided on a partial area of the annular phosphor layer.