Porous Anti-Reflective Layer for Wavelength Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current phosphor wheels in projection devices using laser diodes face challenges with high manufacturing costs, anti-reflective coating issues such as relative film thickness control, thermal matching, coating adhesion, and poor coating drape, which affect the anti-reflective effect and luminous flux.
Innovation Solution
A wavelength conversion element with an anti-reflective layer comprising a first adhesive layer having a plurality of pores, where the thickness is between 500 nm to 3000 nm and pore diameter is between 100 nm to 2500 nm, increasing the light-receiving surface area and enhancing the anti-reflective effect, manufactured by forming a wavelength conversion layer and then an anti-reflective layer using polymer particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a multi-layer optical dielectric coating is used to reduce reflection, then the anti-reflective effect is improved, but the manufacturing cost and process complexity increase due to film thickness control, thermal matching, and coating adhesion issues
Solution Approach 1:
The patent applies a porous anti-reflective layer with controlled pore structures (porosity ratio of 10-80%) to reduce reflection. The porous structure gradually transitions the refractive index from the phosphor layer to air, minimizing reflection across multiple wavelengths without requiring complex multi-layer dielectric coatings. This single porous layer replaces multiple coating layers, simplifying the manufacturing process while maintaining effective anti-reflective performance.
Solution Approach 2:
The patent changes the physical and chemical parameters of the anti-reflective layer by controlling pore diameter (100-2500 nm), porosity ratio (10-80%), and thickness (500-3000 nm). These parameter adjustments optimize the gradual refractive index transition effect, achieving broad-spectrum anti-reflective performance. The soluble polymer particles are removed to create pores, fundamentally changing the layer's optical properties without complex coating processes.
2Object-affected harmful factors
If microstructures such as cones, cylinders, pyramids or prisms are imprinted on the anti-reflective layer, then the anti-reflective effect is improved, but the manufacturing process becomes more complex and requires specialized molds with microstructure patterns
Solution Approach 1:
Instead of imprinting complex geometric microstructures requiring specialized molds, the patent creates a porous structure by dispersing soluble polymer particles in the anti-reflective coating material and removing them after coating. This approach achieves similar light-trapping and anti-reflective effects through controlled porosity without requiring precision molding tools or complex pattern transfer processes.
Solution Approach 2:
The patent extracts the soluble polymer particles from the anti-reflective layer after coating, leaving behind a porous structure. This extraction method creates the desired micro-porous topology without requiring positive molding of complex shapes. The removed polymer particles are replaced by pores, achieving anti-reflective functionality through negative space rather than positive geometric features.
3Object-affected harmful factors
If the anti-reflective layer thickness is increased to improve anti-reflective effect, then reflection is reduced, but the luminous flux is blocked and image brightness decreases
Solution Approach 1:
The porous structure allows the anti-reflective layer to achieve effective reflection reduction through gradual refractive index transition while maintaining high light transmission. The pores create a gradient effect that minimizes reflection at each interface, and the optimized porosity ratio (10-80%) and thickness (500-3000 nm) ensure that sufficient luminous flux passes through to maintain image brightness.
Solution Approach 2:
The patent optimizes the balance between anti-reflective performance and light transmission by precisely controlling the thickness (500-3000 nm) and porosity ratio (10-80%) of the anti-reflective layer. These parameter adjustments ensure the layer is thick enough to provide effective anti-reflective action through gradual refractive index transition but thin and porous enough to allow sufficient luminous flux transmission for maintaining image brightness.
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 increases luminous flux by 15% to 20% and improves the anti-reflective effect, enhancing image brightness and reducing manufacturing costs.
Implementation Method 1
The anti-reflective layer includes a first adhesive layer having a plurality of pores... increasing the light-receiving surface area and enhancing the anti-reflective effect
Implementation Method 2
The anti-reflective layer is disposed on the wavelength conversion layer... improving the anti-reflective effect
Data Source
AI summary
A wavelength conversion element includes a substrate, a wavelength conversion layer and an anti-reflective layer. The wavelength conversion layer is disposed on the substrate. The anti-reflective layer is disposed on the wavelength conversion layer. The anti-reflective layer includes a first adhesive layer having a plurality of pores. A thickness of the anti-reflective layer is 500 nm to 3000 nm, a pore diameter of each of the plurality of pores is 100 nm to 2500 nm, and the thickness of the anti-reflective layer is greater than the pore diameter of the plurality of pores. A manufacturing method of the aforementioned wavelength conversion element is also provided, through which the wavelength conversion element has the anti-reflective effect.