Wavelength Conversion Module Inorganic Bonding Thermal Management
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Solution Overview
Problem
Existing phosphor wheels in projection devices face issues with thermal resistance and reliability due to the degradation of silicone-based materials and the formation of holes during the sintering process, which affects light emitting efficiency and longevity.
Innovation Solution
A wavelength conversion module is developed with a substrate and a wavelength conversion layer that includes a wavelength conversion material dispersed in an inorganic bonding material, featuring first holes filled with a first filling adhesive material to enhance thermal conductivity and heat resistance, and a reflective layer with a scattering material and second filling adhesive material to reduce hole volume and improve reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If silicone-based bonding material is used in the wavelength conversion layer, then the manufacturing process is simple and easy to operate, but the thermal conductivity and heat resistance are poor, leading to degradation under laser irradiation
Solution Approach 1:
The patent changes the material parameter from organic silicone-based bonding material to inorganic bonding material, which fundamentally alters the thermal conductivity and heat resistance properties while maintaining the manufacturing process simplicity
Solution Approach 2:
The patent uses composite materials by combining inorganic bonding material with wavelength conversion material (phosphor powder) to create a wavelength conversion layer that achieves both good thermal conductivity and high conversion efficiency, resolving the contradiction between ease of manufacture and reliability
2Reliability
If inorganic bonding material is used to replace silicone, then thermal conductivity and heat resistance are improved, but holes are formed during sintering or curing process, reducing conversion efficiency
Solution Approach 1:
The patent intentionally creates a controlled porous structure with voids in the wavelength conversion layer, where the voids occupy 5-50% of the total volume. This porous structure allows the inorganic bonding material to maintain good thermal conductivity while accommodating the shrinkage and hole formation during sintering, thus resolving the contradiction between reliability and manufacturing precision
Solution Approach 2:
The patent optimizes the particle size ratio of inorganic bonding material to wavelength conversion material (1:2 to 1:5) and controls the void volume percentage (5-50%) to achieve the best balance between thermal conductivity and conversion efficiency, preventing excessive hole formation while maintaining structural integrity
3Ease of manufacture
If phosphor powder is coated with silicone-based mixture, then the manufacturing process is simple, but the light emitting efficiency deteriorates due to degradation of silicone under long-time laser irradiation
Solution Approach 1:
The patent changes the bonding material from organic silicone to inorganic material, which has superior thermal stability and resistance to laser irradiation. This parameter change prevents degradation under long-time laser exposure while maintaining ease of manufacture through simple coating processes
Solution Approach 2:
The patent uses inexpensive inorganic bonding materials such as glass adhesive or ceramic materials that can withstand high temperatures and laser irradiation without degrading, replacing the short-lived silicone-based materials that deteriorate under thermal stress
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 provides improved thermal conductivity, heat resistance, and reliability of the wavelength conversion module, ensuring high conversion efficiency and extended lifespan, thereby enhancing the performance and reliability of the projection device.
Implementation Method 1
phosphor powder has been excited by an excitation light source to generate a solid color light source
Implementation Method 2
The wavelength conversion layer includes a wavelength conversion material, a first bonding material, and a first filling adhesive material... the inorganic adhesive material and phosphor or the reflective material to form the phosphor wheel. The phosphor wheel formed by applying this manufacturing process has better thermal conductivity
Implementation Method 3
a reflective layer with a scattering material and second filling adhesive material
Data Source
AI summary
A wavelength conversion module, a method for forming a wavelength conversion module, and a projection device are provided. The wavelength conversion module includes a substrate and a wavelength conversion layer. The wavelength conversion layer is located on the substrate and has a plurality of first holes. The wavelength conversion layer includes a wavelength conversion material, a first bonding material, and a first filling adhesive material. The wavelength conversion material is dispersed in the first bonding material. The first filling adhesive material is configured to fill at least a portion of the first holes. The projection device includes the wavelength conversion module, an excitation light source, a light valve, and a projection lens. The wavelength conversion module provided herein has good conversion efficiency and reliability.