Wavelength Conversion Member Oxide Particle Adhesion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing wavelength conversion members in light emitting devices face challenges with phosphor durability due to high light loads, requiring improved adhesion between phosphor particles and the base body, and higher manufacturing simplicity with cost advantages.

Innovation Solution

A wavelength conversion member is created with a phosphor layer including phosphor particles and oxide particles affixed to their surfaces, covered by a continuous cover layer made of the same oxide material, enhancing adhesion and durability, and a manufacturing method that forms these layers on a reflective or light-transmissive base body.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a phosphor layer is used to convert light wavelength, then wavelength conversion is achieved, but adhesion between phosphor particles and base body deteriorates under high light load

Engineering Contradiction:

ImproveadhesionVSAvoidlight load damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces oxide particles as intermediary substances between the phosphor particles and the base body. These oxide particles form a bonding interface that mediates the adhesion relationship, preventing direct contact between phosphor particles and the base body while providing enhanced bonding under high light load conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite structure consisting of phosphor particles, oxide particles, and base body materials. This composite material system combines the light-conversion properties of phosphor with the adhesion-enhancing properties of oxide particles, achieving both wavelength conversion and improved reliability under high light load.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a wavelength conversion member is manufactured with improved adhesion, then durability is enhanced, but manufacturing complexity increases

Engineering Contradiction:

ImprovedurabilityVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the functions of adhesion promotion and wavelength conversion into a single integrated structure. The oxide particles serve dual purposes: enhancing adhesion between phosphor particles and base body, and maintaining the wavelength conversion functionality, thereby improving durability without proportionally increasing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If phosphor particles are densely packed for efficient wavelength conversion, then conversion efficiency improves, but adhesion between particles deteriorates

Engineering Contradiction:

Improvewavelength conversion efficiencyVSAvoidparticle adhesion

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The oxide particles act as intermediary bonding agents between densely packed phosphor particles. This intermediary layer enables close packing of phosphor particles for high conversion efficiency while simultaneously providing adhesion between particles, preventing deterioration despite dense packing.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 improves adhesion between phosphor particles and the base body, enhances light extraction efficiency, and maintains high thermal conductivity, leading to a more durable and efficient wavelength conversion process.

Implementation Method 1

adhesion is improved between the phosphor particles and between the phosphor particles and the base body

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

enhances light extraction efficiency

Methodology Applied

Scientific EffectLight extraction: Refraction

Implementation Method 3

a wavelength conversion member can be in the form of a phosphor wheel used in a projector, which is composed of a phosphor and a resin, and which mainly makes use of a phosphor layer in which a phosphor is fixed with a silicone resin

Methodology Applied

Scientific EffectWavelength conversion: Photoluminescence

Data Source

PatentUS9972751B2Method for manufacturing wavelength conversion member

Publication Date: 2018.05.15 NICHIA CORP

AI summary

A method for manufacturing a wavelength conversion member includes: forming a phosphor layer on a base body including phosphor particles and oxide particles affixed to surfaces of the phosphor particles; and forming a cover layer covering the surfaces of the phosphor particles and surfaces of the oxide particles continuously, and having a same oxide material as the oxide particles. A wavelength conversion member includes: a base body, a phosphor layer disposed on the base body and including phosphor particles and oxide particles affixed to surfaces of the phosphor particles; and a cover layer covering the surfaces of the phosphor particles and surfaces of the oxide particles continuously, and including a same oxide material as the oxide particles.