Wavelength Conversion Element Adhesion via Composite Matrix

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Solution Overview

Problem

There is a challenge in preventing the peeling of the wavelength conversion layer in wavelength conversion elements, which can occur due to differences in thermal expansion coefficients between the layer and the substrate, leading to adherence issues.

Innovation Solution

A wavelength conversion element is designed with an inorganic matrix and a polymer material dispersed within, both in contact with a plate, where the polymer material enhances adherence and thermal conductivity, and the inorganic matrix efficiently dissipates heat, minimizing thermal expansion differences and peeling risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a wavelength conversion layer is formed on a plate, then wavelength conversion function is achieved, but peeling occurs due to thermal expansion coefficient differences

Engineering Contradiction:

Improveadherence of wavelength conversion layerVSAvoidpeeling of wavelength conversion layer

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by combining inorganic particles (for thermal conductivity and structural stability) with organic binder resin (for adhesion and flexibility) in the wavelength conversion layer. This composite structure reconciles the conflicting requirements of thermal management and adherence, preventing peeling while maintaining wavelength conversion functionality.

Inventive Principle:

Principle #40Composite materials

2Strength

If inorganic binder is used to bind phosphor particles, then structural integrity is maintained, but thermal expansion differences cause peeling

Engineering Contradiction:

Improvebinding strength of phosphor particlesVSAvoidadherence to plate

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the material parameter from purely inorganic binder to an organic binder resin, which has different thermal expansion characteristics that better match the plate substrate. This parameter change maintains binding strength while reducing thermal expansion mismatch, thereby improving adherence and preventing peeling.

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If wavelength conversion layer is applied on plate, then optical conversion is achieved, but heat accumulation causes peeling

Engineering Contradiction:

Improvewavelength conversion efficiencyVSAvoidheat accumulation in wavelength conversion layer

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The patent introduces inorganic particles as intermediary elements within the wavelength conversion layer. These particles serve as heat conduction pathways, acting as mediators to transfer heat away from the wavelength conversion layer to the plate substrate, thereby reducing heat accumulation while maintaining conversion efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If polymer material is added to inorganic matrix, then adherence is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveadherence of wavelength conversion layerVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the binder function and polymer adhesion enhancement into a single integrated formulation. The organic binder resin serves both as the binding matrix for inorganic particles and as the adhesive layer to the plate, eliminating the need for separate adhesive layers or complex multi-step manufacturing processes.

Inventive Principle:

Principle #5Merging (Combining)

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 effectively restrains peeling of the wavelength conversion layer by ensuring strong adherence and efficient heat dissipation, maintaining the integrity of the layer on the plate.

Implementation Method 1

The inorganic wavelength conversion material is configured to emit light having a different wavelength than does incident light

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Implementation Method 2

the polymer material enhances adherence and thermal conductivity, and the inorganic matrix efficiently dissipates heat

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20230365856A1Wavelength conversion element, optical apparatus, and method of manufacturing wavelength conversion element

Publication Date: 2023.11.16 SHARP KK

AI summary

A wavelength conversion element includes: a plate; and a wavelength conversion layer disposed on the plate and including: an inorganic matrix; an inorganic wavelength conversion material dispersed in the inorganic matrix and configured to emit light having a different wavelength than does incident light; and a polymer material in the inorganic matrix, wherein both the inorganic matrix and the polymer material are in contact with the plate.