Wavelength Conversion Device with Segmented Reflective Layers
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Solution Overview
Problem
Current laser projectors face challenges in achieving high reflectance for different color light beams due to the limitations of reflective layers, which increases manufacturing costs and affects the brightness and efficiency of the illumination system.
Innovation Solution
A wavelength conversion device with a main body having multiple sections, each configured with different reflective layers aligned to specific wavelength conversion layers, allowing for selective material use and high reflectance for various colors without the need for multilayer coatings, and utilizing a transparent non-metal material for the main body to enhance reflectance and reduce thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single reflective layer with same coating design is used, then the manufacturing cost is low, but the reflectance for different color light beams cannot be high
Solution Approach 1:
The reflective layer is divided into multiple sections (first reflective layer, second reflective layer, etc.) corresponding to different wavelength conversion layers. Each section uses different coating materials optimized for its specific wavelength range, allowing high reflectance for multiple colors while maintaining a relatively simple single-layer structure and manufacturing process.
Solution Approach 2:
Different sections of the reflective layer are assigned different coating materials according to the wavelength conversion layers they correspond to. This local differentiation allows each section to optimize its reflectance for specific colors while the overall structure remains a single reflective layer, balancing performance and manufacturing complexity.
2Illumination intensity
If multilayer coating is adopted to make the reflective layer adapted to reflect different color light beams, then the reflectance for different colors is improved, but the manufacturing cost increases
Solution Approach 1:
Instead of using multiple separate reflective layers, the patent segments the single reflective layer into multiple sections with different coating materials. This approach achieves color-specific reflectance optimization while avoiding the complexity and cost of multilayer coating structures.
Solution Approach 2:
The single reflective layer structure serves multiple functions by incorporating different coating materials in different sections, enabling it to reflect multiple colors effectively. This multi-functional design eliminates the need for separate reflective layers for each color, reducing manufacturing complexity and cost.
3Stability of the object's composition
If a metal substrate is used for the phosphor wheel, then the structure is stable, but the flatness and coating matching ability are poor, resulting in hard to increase reflectance
Solution Approach 1:
The patent changes the material parameter of the substrate from metal to transparent non-metal material. This parameter change improves the flatness and coating matching ability, enabling better coating adhesion and higher reflectance while maintaining structural stability through the rigid nature of transparent non-metal materials.
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 achieves high reflectance for different color light beams, reduces manufacturing costs, and enhances the overall brightness of the projector while preventing overheating issues, thereby improving the performance and efficiency of the illumination system.
Implementation Method 1
The first wavelength conversion layer is adapted to convert the excitation light beam into a first excited light beam having a first wavelength. The second wavelength conversion layer is adapted to convert the excitation light beam into a second excited light beam having a second wavelength
Implementation Method 2
A first reflective layer is disposed on the main body and is aligned to one of the sections. A second reflective layer is disposed on the main body and is aligned to another one of the sections, where materials of the first and second reflective layers are different
Data Source
AI summary
A wavelength conversion device includes a main body, a first reflective layer, a second reflective layer, a first wavelength conversion layer and a second wavelength conversion layer. The main body has at least two sections. The first and second reflective layers are disposed on the main body and aligned to the sections respectively. Materials of the first and second reflective layers are different. The first and second wavelength conversion layers are disposed on the main body and aligned to the first and second reflective layers respectively. The first wavelength conversion layer is adapted to convert an excitation light beam into a first excited light beam having a first wavelength. The second wavelength conversion layer is adapted to convert the excitation light beam into a second excited light beam having a second wavelength. The first and second wavelengths are different. Besides, a projector using the wavelength conversion device is provided.