Reflecting Layer With Multi-Scale Particles for High Reflectivity
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Solution Overview
Problem
The existing reflective inorganic light-emitting color wheels face challenges in achieving high reflectivity and thermal conductivity due to the difficulty in balancing the content of glass powder and diffuser particles, which affects the structural continuity and adhesion of the reflecting layer, and the dispersion of ultrafine nano powders in viscous slurries.
Innovation Solution
A light reflecting material comprising glass powder particles, diffuser particles, and ultrafine nano particles with progressively decreasing particle sizes, where the glass powder particles are ≤5 μm, diffuser particles are 0.1 μm-0.2 μm, and ultrafine nano particles are 0.01 μm-0.05 μm, with specific mass ratios, forming a reticulated structure that increases reflection and refraction surfaces without compromising adhesion, using a method involving ball-milling and sintering on a thermally conductive ceramic substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the content of diffuser particles is increased to obtain sufficiently high reflectivity, then the reflective surface area increases, but the internal structure of the reflecting layer becomes discontinuous and loose, reducing adhesion to substrate and thermal conductivity
Solution Approach 1:
The patent applies parameter changes by using ultrafine nano particles (10 nm-30 nm) instead of conventional larger particles, fundamentally changing the particle size parameter. This enables high reflectivity with only 30%-70% diffuser particle content rather than requiring 80%-90%, because the ultrafine particles provide sufficient reflective surface area while maintaining continuous glass phase structure for adhesion and thermal conductivity
Solution Approach 2:
The patent uses composite materials by combining ultrafine nano particles (Al2O3, TiO2, SiO2, ZrO2) with glass powder in specific ratios. This composite approach allows the reflecting layer to achieve both high reflectivity and good adhesion simultaneously, as the ultrafine particles fill gaps and provide reflection surfaces while the glass phase forms a continuous bonding matrix
2Stability of the object's composition
If the content of glass powder is increased to ensure continuous internal structure and good adhesion, then the structural continuity improves, but the reflectivity decreases due to reduction of reflecting particles
Solution Approach 1:
The patent changes the particle size parameter to ultrafine nano level (10 nm-30 nm), which allows achieving high reflectivity with reduced particle content. This resolves the contradiction by enabling 30%-70% diffuser particle content (with corresponding glass powder) to provide both sufficient reflection surfaces and continuous glass phase structure
Solution Approach 2:
The patent applies local quality by having ultrafine nano particles distributed throughout the glass phase matrix. These particles provide localized reflection surfaces throughout the structure, allowing the glass phase to maintain continuity and adhesion while the dispersed ultrafine particles collectively provide high reflectivity
3Illumination intensity
If ultrafine nano powder is added to increase reflective surface area, then the reflectivity improves, but the slurry viscosity increases and bubble formation occurs due to large specific surface area and surface energy
Solution Approach 1:
The patent uses an intermediary approach by carefully controlling the combination of ultrafine nano particles with glass powder and organic carriers. The glass powder acts as a mediator that helps disperse the ultrafine particles, while the organic carrier facilitates processing. This intermediary system enables the slurry to maintain processability despite the high surface area of ultrafine particles
Solution Approach 2:
The patent changes the particle size parameter to ultrafine nano level and controls the content ratio (30%-70% diffuser particles with corresponding glass powder). This parameter optimization ensures that while enough ultrafine particles are present to provide high reflectivity, the total solid content and surface area are controlled to prevent excessive viscosity and bubble formation during processing
4Illumination intensity
If the particle size of glass powder is reduced below 1 μm to increase reflective surface area, then the reflectivity improves, but it becomes difficult to apply enough external force during ball-milling to achieve further size reduction
Solution Approach 1:
The patent changes the particle size parameter to ultrafine nano level (10 nm-30 nm) through chemical synthesis rather than mechanical ball-milling. This bypasses the limitation of mechanical force application and directly produces the desired ultrafine particles that provide high reflective surface area
Solution Approach 2:
The patent replaces the mechanical ball-milling system with a chemical synthesis system. Instead of using mechanical force to reduce particle size, chemical precipitation and synthesis methods are used to directly produce ultrafine nano particles with controlled size and morphology, achieving 10 nm-30 nm particles that are difficult to obtain mechanically
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
This approach enhances the reflectivity and thermal conductivity of the reflecting layer by increasing the surface area for reflection and refraction while maintaining substrate adhesion, as demonstrated by improved reflectivity and structural integrity in the reflecting layers.
Implementation Method 1
a glass phase having a reticulated structure, the diffuser particles are attached to a surface of the reticulated structure formed by the glass phase
Implementation Method 2
increasing the surface area which can cause reflection or refraction in the reflecting layer
Implementation Method 3
increasing the surface area which can cause reflection or refraction in the reflecting layer
Data Source
AI summary
A light reflecting material, a reflecting layer and a preparation method therefor; the light reflecting material comprises glass powder particles (1), diffuse reflection particles, ultra-fine nano particles and an organic carrier; the particle size of the glass powder particles (1) is ≤5 μm, the particle size of the diffuse reflection particles is 0.1 μm to 0.2 μm, and the particle size of the ultra-fine nano particles is 0.01 μm to 0.05 μm. The glass powder particles (1), diffuse reflection particles and ultra-fine nano particles the particle sizes of which decrease progressively in sequence by one order of magnitude are used as the raw materials of the reflecting layer, without deceasing the adhesion between the reflecting layer and a substrate, the surface area within the reflecting layer that may cause reflection or refraction is increased to obtain better reflectivity.