Wavelength Conversion Member Laser Machining for Inclined Surfaces
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Solution Overview
Problem
Existing methods for manufacturing wavelength conversion members with phosphor layers, such as etching and mechanical machining, face challenges in achieving precise shapes due to material differences and tool wear, making it difficult to form intended inclined surface structures.
Innovation Solution
A method using a pulsed laser beam to create continuous machining marks at different processing depths, allowing for the formation of depressed portions with desired shapes in wavelength conversion members, which include both phosphor and light-transmissive portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If etching with lithography technique is used to form inclined surface structures, then the structures can be formed on the phosphor layer surface, but differences in etching rates between materials make it difficult to obtain the intended shape
Solution Approach 1:
The patent replaces the chemical etching process with a mechanical laser machining process. The laser beam directly ablates the phosphor layer material to form inclined surface structures, eliminating the need for chemical etchants and avoiding the problem of differential etching rates between mixed materials. This substitution of mechanical energy for chemical processes enables precise shape control regardless of material composition variations.
Solution Approach 2:
The patent utilizes controllable laser parameters (power, pulse duration, scanning speed, focal position) to precisely control the machining process. By adjusting these parameters, the inclined surface structures can be formed with high precision and consistent geometry, overcoming the limitations of etching rate variations that occur with different material compositions in chemical etching processes.
2Shape
If mechanical machining using a blade is used to form depressed portions, then the phosphor layer can be machined, but the shape changes as machining progresses due to blade wear
Solution Approach 1:
The patent replaces mechanical blade machining with laser beam machining. The laser provides contactless material removal through localized heating and vaporization, eliminating blade wear entirely. This ensures that the depressed portion shapes remain consistent throughout the machining process, as the laser parameters can be precisely controlled and maintained without physical degradation of the cutting tool.
Solution Approach 2:
The laser beam system is self-sharpening in the sense that it does not suffer from wear like mechanical blades. The focal point and energy distribution of the laser can be maintained consistently through optical system adjustments, allowing the machining process to maintain precision throughout operation without requiring tool replacement or reconditioning.
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
This approach enables the precise formation of inclined surfaces, reducing material processing rate differences and tool wear issues, resulting in wavelength conversion members with improved shape accuracy and light extraction efficiency.
Implementation Method 1
forming, in the wavelength conversion member, at least one depressed portion each having an inclined surface inclined with respect to the upper surface by irradiating the wavelength conversion member with a pulsed laser beam from above more than once to form a plurality of continuous machining marks at different processing depths
Data Source
AI summary
A wavelength conversion member manufacturing method includes: providing the wavelength conversion member having an upper surface, the wavelength conversion member including a phosphor portion, and a light-transmissive portion configured to transmit fluorescence from the phosphor portion; and forming, in the wavelength conversion member, at least one depressed portion each having an inclined surface inclined with respect to the upper surface by irradiating the wavelength conversion member with a pulsed laser beam from above more than once to form a plurality of continuous machining marks at different processing depths.