Wavelength Conversion Element With Protective Layer And Porous Phosphor
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Solution Overview
Problem
Wavelength conversion elements with phosphor light sources face challenges in increasing output power and reliability due to heat management issues, particularly with metal ions eluting into the refrigerant and causing deposits that absorb and scatter light, reducing efficiency.
Innovation Solution
A wavelength conversion element design featuring a phosphor layer, refrigerant, and refrigerant transport member encapsulated in a housing with a protective layer on the inner wall to prevent metal ion elution, and a porous phosphor layer with varying pore sizes to enhance cooling efficiency and prevent foreign object entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the phosphor layer is cooled by circulating refrigerant in contact with the housing, then cooling efficiency is improved, but metal ions elute into the refrigerant causing deposits that reduce light output
Solution Approach 1:
A protective layer is introduced as an intermediary between the housing and the refrigerant. This protective layer prevents direct contact between the refrigerant and the housing, thereby preventing metal ion elution into the refrigerant while maintaining the cooling function. The protective layer acts as a barrier that mediates between the cooling system and the housing material.
Solution Approach 2:
The protective layer is applied in advance to the housing inner wall before the refrigerant circulation begins. This preliminary protective measure prevents the harmful elution of metal ions from occurring in the first place, rather than attempting to remove deposits after they form.
2Ease of manufacture
If the phosphor layer has uniform pore size, then manufacturing is simplified, but cooling performance is insufficient and foreign objects can enter the light emitting section
Solution Approach 1:
The phosphor layer is designed with non-uniform pore sizes, where different regions have different pore characteristics. The light emitting section has smaller pores to prevent foreign object entry, while other regions have larger pores to facilitate refrigerant circulation and cooling. This local variation in pore quality optimizes both cooling performance and contamination prevention.
Solution Approach 2:
The phosphor layer utilizes a porous structure with controlled pore size distribution. The porous structure allows refrigerant to penetrate and cool the phosphor particles effectively, while the varying pore sizes provide both cooling efficiency and filtration function to prevent foreign object entry.
3Power
If laser power is increased to boost output, then light output power increases, but heat generation increases causing reliability issues
Solution Approach 1:
The refrigerant system utilizes phase transitions (liquid to vapor and back) to absorb and remove heat from the phosphor layer. As the refrigerant circulates through the porous phosphor layer, it undergoes phase change that efficiently absorbs the heat generated by high-power laser excitation, enabling sustained high output power operation.
Solution Approach 2:
A liquid refrigerant circulation system is implemented to actively remove heat from the phosphor layer. The refrigerant is pumped through the porous structure of the phosphor layer, providing continuous heat removal that enables the system to operate at high power levels without thermal damage.
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 output power and reliability by preventing metal ion deposits and improving cooling performance, stabilizing light source output and image quality in projection display applications.
Implementation Method 1
The refrigerant cools the phosphor layer
Implementation Method 2
The refrigerant cools the phosphor layer
Implementation Method 3
The housing includes a protective layer on at least a portion of an inner wall... This suppresses contact between the refrigerant and the housing
Implementation Method 4
The phosphor layer has a porous structure therein. The porous structure changes in average pore size from one surface to a light emitting section on another surface
Implementation Method 5
The phosphor layer includes a plurality of phosphor particles... A wavelength conversion element including a phosphor as a light source
Data Source
AI summary
A first wavelength conversion element according to an embodiment of the present disclosure includes: a phosphor layer; a refrigerant; a refrigerant transport member; and a housing. The phosphor layer includes a plurality of phosphor particles. The phosphor layer has a gap therein. The refrigerant cools the phosphor layer. The refrigerant transport member is provided in contact with the phosphor layer. The refrigerant transport member circulates the refrigerant. The housing encapsulates the phosphor layer, the refrigerant, and the refrigerant transport member. The housing includes a protective layer on at least a portion of an inner wall.