Phosphor Wheel Sintered Layers for Guide-Pin Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional phosphor wheels using mixed layer type wavelength conversion layers are cost-effective but have issues with conversion efficiency and heat resistance, while sintered body type wavelength conversion layers offer superior efficiency and heat resistance but face challenges in alignment due to the absence of pins for alignment between adjoining layers.
Innovation Solution
A phosphor wheel design featuring a rotatable base plate with adjoining first and second sintered body type wavelength conversion layers, separated by an adhesive layer, where the layers have non-contacting ends to facilitate alignment using guide pins, ensuring secure attachment and high conversion efficiency and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sintered body type wavelength conversion layers are used, then conversion efficiency and heat resistance are improved, but alignment difficulty increases due to absence of pins for alignment between adjoining layers
Solution Approach 1:
The wavelength conversion layer is divided into multiple independent sintered body type layers (first wavelength conversion layer, second wavelength conversion layer, etc.) that can be separately manufactured and then assembled. Each layer can be independently optimized for specific wavelength conversion functions while maintaining the ability to align them through the adhesive layer structure.
Solution Approach 2:
An adhesive layer is introduced as an intermediary between the base plate and the sintered body type wavelength conversion layers. This adhesive layer serves as a mediator that provides both secure attachment and alignment functionality, allowing pins to be embedded within it for precise alignment of multiple layers during assembly.
2Temperature
If sintered body type wavelength conversion layers are used, then heat resistance is improved, but alignment difficulty increases due to absence of pins for alignment between adjoining layers
Solution Approach 1:
The wavelength conversion layer is divided into multiple independent sintered body type layers (first wavelength conversion layer, second wavelength conversion layer, etc.) that can be separately manufactured and then assembled. Each layer can be independently optimized for specific wavelength conversion functions while maintaining the ability to align them through the adhesive layer structure.
Solution Approach 2:
An adhesive layer is introduced as an intermediary between the base plate and the sintered body type wavelength conversion layers. This adhesive layer serves as a mediator that provides both secure attachment and alignment functionality, allowing pins to be embedded within it for precise alignment of multiple layers during assembly.
3Ease of manufacture
If mixed layer type wavelength conversion layer is used, then cost is reduced, but conversion efficiency and heat resistance deteriorate
Solution Approach 1:
The invention uses composite material structure by combining multiple sintered body type wavelength conversion layers with different phosphor particles (e.g., yellow phosphor, green phosphor, red phosphor) in a layered configuration. Each layer contains specific phosphor particles optimized for particular wavelength conversions, creating a composite system that achieves high conversion efficiency and heat resistance while maintaining cost-effectiveness through modular assembly.
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 design achieves excellent conversion efficiency and heat resistance by allowing secure alignment of sintered body type wavelength conversion layers, overcoming the limitations of conventional methods.
Implementation Method 1
a first sintered body type wavelength conversion layer having a sintered body of first wavelength conversion particles that wavelength-convert excitation light into light with a first wavelength
Implementation Method 2
an adhesive layer disposed between the base plate and the plurality of wavelength conversion layers
Data Source
AI summary
A phosphor wheel includes: a rotatable base plate; a plurality of wavelength conversion layers arranged on the base plate, and including a first and a second sintered body type wavelength conversion layer which are arranged adjoining each other in a circumferential direction around a center of rotation of the base plate, the first having a sintered body of first wavelength conversion particles that wavelength-convert excitation light into a first wavelength, the second having a sintered body of second wavelength conversion particles that wavelength-convert the excitation light into a second wavelength different from the first wavelength; and an adhesive layer between the base plate and the plurality of wavelength conversion layers, wherein at a boundary where the first and second layers adjoin each other, the first layer having at its end in the circumferential direction a site not in contact with an end of the second layer in the circumferential direction.