Wavelength Conversion Device Heat Dissipation Layer
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Solution Overview
Problem
Current projector systems experience brightness decay and potential failure of fluorescent glue due to high temperatures, as the thermal conductivity of the fluorescent glue is less than 1 W/mK, leading to significant issues above 150°C and complete failure above 200°C.
Innovation Solution
A wavelength conversion device with a substrate, heat-conducting connection structure, first reflective structure, and wavelength conversion structure is designed to rapidly transfer thermal energy away from the wavelength conversion structure, preventing rapid temperature increases and alleviating brightness decay by using materials with improved thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fluorescent glue is used as the wavelength conversion material, then the device can be manufactured with conventional materials and processes, but the thermal conductivity is low (less than 1 W/mK) causing brightness decay above 150°C and failure above 200°C
Solution Approach 1:
The patent uses a composite structure consisting of a wavelength conversion layer (containing phosphor particles) and a heat dissipation layer (with high thermal conductivity material). This composite design combines the wavelength conversion function with efficient heat dissipation, solving both the optical conversion requirement and the thermal management problem simultaneously.
Solution Approach 2:
The heat dissipation layer acts as an intermediary between the wavelength conversion layer and the substrate. It mediates the thermal energy transfer, conducting heat away from the phosphor particles efficiently while maintaining the optical conversion function, thereby preventing brightness decay and material failure.
2Device complexity
If conventional fluorescent glue is used, then the structure is simple and easy to manufacture, but the thermal conductivity is insufficient leading to temperature increase and brightness decay
Solution Approach 1:
The patent creates a composite wavelength conversion device with distinct functional layers: a wavelength conversion layer containing phosphor particles and a heat dissipation layer with high thermal conductivity material. This composite structure addresses thermal management while maintaining manufacturing feasibility.
Solution Approach 2:
The wavelength conversion device is segmented into functional layers: the wavelength conversion layer and the heat dissipation layer. This segmentation allows each layer to perform its specific function optimally - optical conversion in one layer and thermal management in another - without excessive overall complexity.
3Illumination intensity
If the phosphor is excited by high-power excitation beam, then the illumination intensity is improved, but the temperature of the phosphor ramps up above 150°C causing brightness decay
Solution Approach 1:
The patent converts the harmful thermal energy generated during phosphor excitation into a manageable parameter by introducing a heat dissipation layer. This layer captures and conducts away the excess heat, allowing the system to operate at high illumination intensities without suffering from temperature-induced brightness decay.
Solution Approach 2:
The heat dissipation layer serves as a thermal intermediary between the excited phosphor particles and the environment. It efficiently conducts heat away from the high-power excitation zone, enabling sustained high brightness operation without temperature ramp-up above 150°C.
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 lowers the temperature of the wavelength conversion device by 10-100°C and increases its temperature resistance by 10-100°C, while also raising brightness by 5-50% compared to traditional systems using fluorescent glue.
Implementation Method 1
The heat-conducting connection structure is located between the first surface of the substrate and the first reflective structure. The wavelength conversion structure is disposed on the first reflective structure and around the axis center. The first reflective structure is located between the wavelength conversion structure and the heat-conducting connection structure.
Implementation Method 2
The phosphor of a phosphor wheel will be excited after being irradiated by an excitation beam provided by an excitation light source. The phosphor is formed by coating fluorescent glue on a substrate.
Data Source
AI summary
A projector and a wavelength conversion device thereof are provided. The projector includes an illumination system that includes a light source device and a wavelength conversion device. The light source device is configured to provide an excitation beam. The wavelength conversion device is disposed on a transmission path of the excitation beam, and configured to convert the excitation beam into an illumination beam. The wavelength conversion device includes a substrate comprising a first surface, a second surface, and an axis center, a heat-conducting connection structure, a first reflective structure, and a wavelength conversion structure. The heat-conducting connection structure is located between the first surface and a first reflective structure, the first reflective structure is located between the heat-conducting connection structure and a wavelength conversion structure, and the wavelength conversion structure is located on the first reflective structure.