Wavelength Conversion Module Diffuse Reflection Layer Design
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Solution Overview
Problem
Existing diffuse reflection layers in projection apparatuses face issues with cracks and non-uniformity due to shrinkage during curing, and have low reflectivity and thermal conductivity, particularly with materials like aluminum oxide, which is prone to aging under high temperature and humidity conditions.
Innovation Solution
A wavelength conversion module using a diffuse reflection layer with two types of particles, where the second particles are 0.3% to 7% of the volume of the first particles and have higher whiteness, filling gaps and increasing contact area and reflectivity, and a colloid to enhance thermal dissipation and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If single type diffuse reflection particles with particle size close to visible light wavelength are used, then reflectivity is improved, but cracks occur in the diffuse reflection layer due to shrinkage during curing
Solution Approach 1:
The patent applies local quality by using particles of different sizes in different regions of the diffuse reflection layer. The first particles (400-700nm) provide high reflectivity where needed, while the second particles (smaller size) fill gaps and reduce shrinkage stress, preventing cracks. This creates a heterogeneous structure where different particle sizes serve different functional purposes within the same layer.
2Reliability
If aluminum oxide is used as diffuse reflection material, then stability and heat resistance are improved, but reflectivity is reduced due to lower refractive index
Solution Approach 1:
The patent uses a composite material system combining aluminum oxide particles (providing stability and heat resistance) with a transparent resin matrix (enhancing reflectivity). The resin material has higher refractive index than aluminum oxide, creating additional refraction and reflection at interfaces. This composite approach allows simultaneous achievement of mechanical stability and optical performance.
3Illumination intensity
If high refractive index materials are used for diffuse reflection particles, then reflectivity is improved, but thermal conductivity is reduced
Solution Approach 1:
The patent introduces the transparent resin material as an intermediary substance that mediates between the aluminum oxide particles and the surrounding environment. The resin has intermediate thermal conductivity properties, facilitating heat transfer from the high-refractive-index particles while maintaining their optical advantages. This intermediary material enables simultaneous optimization of optical and thermal properties.
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 improves light efficiency, heat dissipation, and reliability by increasing reflectivity and reducing shrinkage-related issues, with enhanced thermal conductivity and uniformity in the diffuse reflection layer.
Implementation Method 1
After the phosphor layer is excited by excitation light, it emits fluorescent light with a corresponding wavelength
Implementation Method 2
the diffuse reflection layer is used to reflect the fluorescent light
Implementation Method 3
the heat energy is conducted to the substrate through the diffuse reflection layer for heat dissipation
Data Source
AI summary
A wavelength conversion module including a substrate, a wavelength conversion layer and a diffuse reflection layer is provided. The wavelength conversion layer is disposed on the substrate, and the diffuse reflection layer is disposed between the substrate and the wavelength conversion layer. The diffuse reflection layer includes a plurality of first diffuse reflection particles and a plurality of second diffuse reflection particles, wherein a volume of each second diffuse reflection particle is 0.3% to 7% of an average volume of the first diffuse reflection particles, and a whiteness of the second diffuse reflection particles is greater than or equal to a whiteness of the first diffuse reflection particles. A projection apparatus is also provided.