Tapered Cavity Static Phosphor Module for Uniform Illumination

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Solution Overview

Problem

Conventional laser excited static phosphor light sources in projector devices face challenges such as high cost, thermal quenching, and inefficiencies due to focused laser spots and rotating phosphor wheels, which result in non-uniform light intensity and increased manufacturing complexity.

Innovation Solution

The use of static phosphor modules with a tapered cavity design and highly reflective interior surfaces to distribute laser light uniformly and reduce thermal quenching, eliminating the need for rotating phosphor wheels and additional optical components, while maintaining excellent thermal performance and cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If rotating phosphor wheels are used to distribute light uniformly, then illumination uniformity is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveillumination uniformityVSAvoiddevice complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent removes the rotating phosphor wheel mechanism entirely and replaces it with a static phosphor module. The light distribution function previously achieved through rotation is now accomplished through the geometric design of the static module, including tapered cavities and reflective surfaces, eliminating mechanical complexity while maintaining uniform illumination.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical rotation system is replaced with an optical solution using static phosphor modules with specifically designed geometries. The tapered cavity shapes and internal reflective surfaces work together to distribute laser-excited light uniformly without requiring any moving parts, substituting mechanical motion with optical geometry.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If focused laser spots are used to excite phosphor, then laser efficiency is improved, but thermal quenching increases

Engineering Contradiction:

Improvelaser efficiencyVSAvoidthermal quenching

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

Instead of using a single focused laser spot, the patent divides the excitation into multiple distributed spots across the phosphor surface. Each spot is smaller and more efficiently excited by laser, but the collection of spots covers a larger area, distributing the thermal load and reducing quenching while maintaining overall laser efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from point-like focused spots to a distributed two-dimensional array of excitation points. This dimensional expansion allows multiple laser spots to illuminate different regions of the phosphor simultaneously, reducing thermal concentration at any single point while maintaining efficient laser energy utilization.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Illumination intensity

If additional optical components are added to distribute light, then illumination uniformity is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveillumination uniformityVSAvoidmanufacturing complexity

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent combines multiple functions into the single static phosphor module structure. The tapered cavities serve both as structural support and as light-distributing elements, while the internal reflective surfaces simultaneously guide and uniformize the light output. This integration eliminates the need for separate optical components and simplifies manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The static phosphor module with tapered cavities and reflective surfaces performs multiple functions simultaneously: it distributes light uniformly, manages thermal load, and eliminates the need for external optical components. This multi-functionality reduces the overall component count and simplifies manufacturing while achieving the desired illumination uniformity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution enhances illumination uniformity, reduces manufacturing complexity, and increases brightness and efficiency, leading to improved projector performance with reduced costs and thermal issues.

Implementation Method 1

a phosphor configured to emit light when energized by incoming light

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Implementation Method 2

highly reflective interior surfaces to distribute laser light uniformly

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS11340520B2Apparatus for high efficiency laser static phosphor module

Publication Date: 2022.05.24 TEXAS INSTRUMENTS INC

AI summary

In described examples, a body includes an opening in a central portion of a surface, a cavity having sides extending from the opening into the body, and a bottom surface within the body supporting a phosphor configured to emit light when energized by incoming light. In a further arrangement, the sides are tapered from the opening to the bottom surface, such that a cross sectional area of the opening is greater than a cross sectional area of the bottom surface.