Wavelength-Converting Component With Polyimide Reflective Layer
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Solution Overview
Problem
Conventional phosphor wheels in high-power laser projection apparatuses face issues with thermal conductivity and temperature resistance due to the use of highly transparent silica gel, leading to degradation in image brightness and mechanical properties.
Innovation Solution
A wavelength-converting component is developed with a substrate, a wavelength-converting layer, and a reflective layer that includes diffuse reflection particles mixed in an aromatic polyimide-based adhesive, which is cured at lower temperatures (200° C. to 300° C.) to improve mechanical and thermal properties, reducing moisture absorption and pore formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If glass-based material is used instead of highly transparent silica gel, then temperature resistance and thermal conductivity are improved, but the material requires heat curing at high temperature greater than 400° C. and develops more pores after curing
Solution Approach 1:
The patent changes the curing temperature parameter from high temperature (>400° C.) to low temperature (200-300° C.) by using aromatic polyimide as the adhesive material. This parameter change allows the reflective layer to be formed without excessive heat, preventing pore formation while still achieving adequate temperature resistance for the application.
Solution Approach 2:
The patent uses a composite material consisting of aromatic polyimide adhesive mixed with reflective particles (aluminum powder, titanium dioxide, or zinc oxide). This composite approach combines the benefits of the adhesive material with the reflective properties needed, while the low curing temperature of the aromatic polyimide prevents pore formation that would occur with traditional glass-based materials requiring >400° C. curing.
2Loss of energy
If glass-based material is used instead of highly transparent silica gel, then thermal conductivity is improved, but the cured material has more pores which may affect thermal conductivity
Solution Approach 1:
The patent changes the curing temperature parameter to 200-300° C., which is sufficiently high to cure the aromatic polyimide adhesive but low enough to prevent excessive pore formation. This optimized temperature parameter ensures good thermal conductivity by maintaining material density while achieving proper curing.
Solution Approach 2:
The composite of aromatic polyimide with reflective particles creates a material that maintains good thermal conductivity. The aromatic polyimide matrix provides a continuous phase for heat transfer, and the low curing temperature prevents pore formation that would disrupt thermal pathways, thus maintaining energy efficiency.
3Ease of manufacture
If conventional adhesive materials are used, then ease of manufacture is maintained, but mechanical properties such as shear strength, tensile strength and fatigue strength are insufficient
Solution Approach 1:
The patent uses aromatic polyimide as the adhesive material in the reflective layer. Aromatic polyimide is known for its excellent mechanical properties including high shear strength, tensile strength, and fatigue strength. This composite material maintains ease of manufacture through simple mixing and low-temperature curing while dramatically improving the mechanical strength of the wavelength-converting component.
Solution Approach 2:
The patent changes the adhesive material parameters by selecting aromatic polyimide, which has superior mechanical properties compared to conventional adhesives. The low curing temperature (200-300° C.) of aromatic polyimide also simplifies the manufacturing process, maintaining ease of manufacture while achieving the required mechanical strength for high-power laser applications.
4Ease of manufacture
If conventional adhesive materials are used, then ease of manufacture is maintained, but temperature resistance is insufficient
Solution Approach 1:
The patent employs aromatic polyimide as the adhesive material, which is renowned for its exceptional temperature resistance and thermal stability. This composite material can withstand the high temperatures generated by high-power laser diodes without degrading, while still being manufacturable through low-temperature curing (200-300° C.), thus maintaining ease of manufacture.
Solution Approach 2:
The patent changes the thermal parameters of the adhesive material by selecting aromatic polyimide, which has a high glass transition temperature and excellent thermal stability. The curing temperature parameter is optimized to 200-300° C., which is sufficient to cure the aromatic polyimide and achieve the required temperature resistance for high-power laser applications, while remaining manageable for manufacturing processes.
5Ease of manufacture
If highly transparent silica gel is used, then ease of manufacture is maintained, but moisture absorption rate is high
Solution Approach 1:
The patent uses aromatic polyimide as the adhesive material in the reflective layer. Aromatic polyimide has inherently low moisture absorption characteristics due to its chemical structure. This composite material maintains ease of manufacture through simple processing and low-temperature curing while providing excellent resistance to moisture absorption, preventing degradation from humidity exposure.
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 solution enhances shear strength, tensile strength, fatigue strength, and temperature resistance while reducing moisture absorption, thereby improving the durability and performance of the wavelength-converting component and reducing image brightness degradation in projection apparatuses.
Implementation Method 1
the first organic adhesive includes an aromatic polyimide
Implementation Method 2
a blue laser diode is used to excite the phosphor powder on the phosphor wheel to generate yellow light and green light
Implementation Method 3
The reflective layer includes a plurality of diffuse reflection particles and a first organic adhesive
Data Source
AI summary
A manufacturing method of a wavelength-converting component includes providing a substrate, providing a wavelength-converting layer and providing a reflective layer. The reflective layer is disposed on the substrate. The wavelength-converting layer is disposed on a surface of the reflective layer away from the substrate. The wavelength-converting layer includes a wavelength-converting material and a second organic adhesive. The wavelength-converting material is mixed in the second organic adhesive. The second organic adhesive includes an aromatic polyimide. The wavelength-converting component manufactured by the method of the invention can improve mechanical properties such as shear strength, tensile strength and fatigue strength, temperature resistance and reflectivity, and can reduce rates of moisture absorption. The projection apparatus including the wavelength-converting component can reduce degradation in image brightness.