Wavelength Conversion Device with Dual Adhesive Layers
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Solution Overview
Problem
Conventional phosphor wheels in projectors face limitations in increasing phosphor powder concentration due to reduced adhesive force, leading to decreased wavelength conversion efficiency and structural reliability, especially when exposed to high-speed spinning and centrifugal forces.
Innovation Solution
A wavelength conversion device with a substrate, first and second glue substances, and a wavelength conversion structure, where the wavelength conversion structure is attached to the substrate via the first glue substance and connected to the second glue substance, enhancing structural strength and reliability, and utilizing reflective properties of the glue substances to increase wavelength conversion efficiency by reflecting or scattering the exciting beam back for re-excitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the concentration of phosphor powders in the phosphor glue is increased, then the wavelength conversion efficiency is improved, but the bonding force between the phosphor glue and the metal disc decreases
Solution Approach 1:
The patent divides the adhesive layer into two distinct functional layers: a first adhesive layer containing phosphor powders for wavelength conversion, and a second adhesive layer containing high reflective material for reflecting laser beams. This segmentation allows each layer to be optimized independently - the first layer can have high phosphor concentration for efficiency, while the second layer provides structural bonding and optical reflection functions.
Solution Approach 2:
The patent introduces a high reflective material layer as an intermediary between the phosphor glue and the metal disc. This intermediary layer serves dual purposes: it reflects the laser beam back to the phosphor powders to enhance wavelength conversion efficiency, and it provides strong bonding to the metal disc to maintain structural integrity at high speeds.
2Productivity
If the phosphor wheel spins at high speed, then the productivity is improved, but the phosphor glue is easy to separate from the metal disc due to centrifugal force
Solution Approach 1:
By separating the adhesive layer into two distinct layers, the patent ensures that the second adhesive layer with high reflective material is directly bonded to the metal disc, providing strong structural attachment that can withstand high-speed rotation. The first adhesive layer with phosphor powders is bonded to the second layer, creating a stable multi-layer structure that maintains reliability at high spinning speeds.
3Productivity
If the concentration of phosphor powders is increased, then the wavelength conversion efficiency is improved, but the lateral sides of the excited phosphor glue leak light that influences the whole luminous efficiency
Solution Approach 1:
The high reflective material layer acts as an intermediary that reflects laser beams back to the phosphor powders, preventing light leakage from the lateral sides. This reflective intermediary ensures that excitation light is directed through the phosphor layer multiple times, maximizing wavelength conversion efficiency while preventing energy loss through lateral leakage.
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 design significantly improves the structural strength and reliability of the wavelength conversion device while enhancing luminous efficiency by effectively increasing the wavelength conversion efficiency through reflective and scattering mechanisms.
Implementation Method 1
utilizing reflective properties of the glue substances to increase wavelength conversion efficiency by reflecting or scattering the exciting beam back for re-excitation
Implementation Method 2
reflecting or scattering the exciting beam back for re-excitation
Implementation Method 3
the illumination system can generate illumination beams with different colors, where its main principle is that the utilization of the good luminous efficiency of an exciting light source, such as light emitting diode (LED) or laser diode (LD) to excite phosphor powders on a phosphor wheel, thereby generating a monochromatic beam
Data Source
AI summary
A wavelength conversion device includes a substrate, a first glue substance, a wavelength conversion structure, and a second glue substance. The substrate includes a first surface, a second surface, and an axis. The first glue substance is disposed between the wavelength conversion structure and the first surface and surrounds the axis. The wavelength conversion structure is disposed on the first glue substance and surrounds the axis. The wavelength conversion structure includes a first bonding surface, a first lateral surface, and a second lateral surface. The first bonding surface faces to the first glue substance and is connected between the first lateral surface and the second lateral surface. The first lateral surface faces in the direction away from the axis, whereas the second lateral surface faces in the direction close to the axis. The second glue substance is connected to the first lateral surface and surrounds the axis.