Wavelength Conversion Element Layout for Projector Heat Dissipation
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Solution Overview
Problem
Solid state illumination projectors using high thermal conductivity substrates for phosphor wheels face high manufacturing costs and processing difficulties due to their hardness, limiting mass production and projection quality.
Innovation Solution
A wavelength conversion element with a substrate, wavelength conversion layer, reflective layer, and heat conductive layer, where at least a portion of the heat conductive layer is located between the substrate and the reflective layer, enhancing thermal conductivity and conversion efficiency without requiring expensive high thermal conductivity substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high thermal conductivity substrates are used for phosphor wheels, then heat dissipation performance is improved, but manufacturing cost increases and processing becomes more difficult
Solution Approach 1:
The substrate is divided into two functional layers: a lower support substrate layer and an upper heat dissipation layer. The support substrate can be made of low-cost, easy-to-process materials, while the heat dissipation layer is specifically designed with high thermal conductivity materials to handle heat from the phosphor wheel, separating structural support functions from thermal management functions
Solution Approach 2:
The substrate uses a composite structure combining different materials with complementary properties. The support substrate may use conventional materials for ease of manufacturing, while the heat dissipation layer employs high thermal conductivity materials such as metal ceramics or aluminum nitride to achieve superior heat dissipation performance without requiring the entire substrate to be made of expensive, difficult-to-process high-performance materials
2Temperature
If high thermal conductivity substrates are used, then heat dissipation is improved, but conversion efficiency decreases due to higher manufacturing costs
Solution Approach 1:
High thermal conductivity properties are applied locally only where heat dissipation is critical (the heat dissipation layer in contact with or near the phosphor wheel), rather than requiring the entire substrate to have high thermal conductivity. This localized approach achieves effective heat management while reducing overall material costs and improving cost-effective conversion efficiency
3Temperature
If high hardness substrates with high thermal conductivity are used, then heat dissipation is improved, but processability deteriorates
Solution Approach 1:
The substrate structure is segmented into a support substrate layer that can be easily processed with conventional materials, and a heat dissipation layer that provides thermal management. This segmentation allows the majority of the substrate to maintain good processability while the critical heat dissipation zone achieves high thermal conductivity
Solution Approach 2:
The substrate uses different material parameters for different layers: the support substrate uses materials optimized for ease of processing and manufacturing, while the heat dissipation layer uses materials with high thermal conductivity. This parameter differentiation allows each layer to be optimized for its specific function without compromising overall manufacturability
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 improves heat dissipation and conversion efficiency, leading to favorable projection quality and product competitiveness by reducing the need for costly substrates and addressing processing difficulties.
Implementation Method 1
the heat conductive layer is disposed on the substrate, and at least a portion of the heat conductive layer is located between the substrate and the reflective layer
Implementation Method 2
The blue laser light source is projected on the light conversion region of the phosphor wheel through the lens, so as to excite the yellow light source to achieve light combination
Implementation Method 3
The reflective layer is disposed on the substrate and is located between the substrate and the wavelength conversion layer
Data Source
AI summary
A wavelength conversion element is provided. The wavelength conversion element includes a substrate, a wavelength conversion layer, a reflective layer, and a heat conductive layer. The wavelength conversion layer is disposed on the substrate. The reflective layer is disposed on the substrate and is located between the substrate and the wavelength conversion layer. The heat conductive layer is disposed on the substrate, and at least a portion of the heat conductive layer is located between the substrate and the reflective layer. A projector is also provided, and the projector includes the wavelength conversion element. The wavelength conversion element exhibits a favorable heat dissipation effect and provides improved conversion efficiency, so that the projector exhibits favorable projection quality and product competitiveness.