Wavelength Conversion Member Phosphor Binder Optimization
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Solution Overview
Problem
Current light-emitting devices in projectors face challenges in achieving high light emission efficiency due to limitations in wavelength conversion efficiency and light collection efficiency, which affect the overall performance and brightness of the projected images.
Innovation Solution
A wavelength conversion member is developed, comprising a substrate with a wavelength conversion layer containing a binder and phosphor, with specific volume ratios and thickness ranges (0.75 to 1.45 and 55 μm to 146 μm, respectively) to enhance fluorescence efficiency and light collection, and a manufacturing method involving a phosphor composition with a solvent of boiling point 200° C. to 300° C. and mass ratios of solvent to binder and phosphor to binder within certain ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the wavelength conversion layer uses conventional phosphor concentration and thickness, then the manufacturing process is simple, but the fluorescence efficiency and light collection efficiency are insufficient
Solution Approach 1:
The patent applies parameter changes by optimizing the phosphor to binder volume ratio within the specific range of 0.75 to 1.45, and controlling the wavelength conversion layer thickness between 55 μm to 146 μm. These precise parameter adjustments maximize fluorescence efficiency while maintaining manufacturability, resolving the contradiction between energy loss reduction and manufacturing precision requirements.
Solution Approach 2:
The patent uses composite materials by formulating a phosphor composition containing phosphor particles, binder, and solvent in specific proportions. This composite structure allows the wavelength conversion layer to achieve both high fluorescence efficiency through optimized phosphor distribution and ease of manufacturing through proper rheological properties of the composition.
2Loss of energy
If the wavelength conversion layer thickness is increased to improve light collection, then more light can be collected, but the surface temperature increases and efficiency decreases
Solution Approach 1:
The patent resolves this contradiction by optimizing the wavelength conversion layer thickness to a specific range of 55 μm to 146 μm. This parameter optimization ensures sufficient light collection efficiency while preventing excessive heat accumulation that would occur with thicker layers, thereby maintaining low surface temperature and high overall efficiency.
Solution Approach 2:
The patent applies partial action by using a moderate phosphor concentration (volume ratio 0.75 to 1.45) rather than maximum concentration. This partial optimization achieves adequate fluorescence conversion while avoiding the heat generation problems that would result from excessive phosphor loading, thus balancing light collection with temperature control.
3Loss of energy
If high phosphor concentration is used to improve fluorescence efficiency, then more light conversion occurs, but the mixture becomes difficult to apply uniformly
Solution Approach 1:
The patent uses composite materials by formulating a phosphor composition with phosphor, binder, and solvent in optimized ratios. The binder and solvent create a workable slurry that maintains high phosphor content (volume ratio 0.75 to 1.45) while ensuring proper flow properties and uniform applicability, resolving the contradiction between fluorescence efficiency and ease of manufacture.
Solution Approach 2:
The patent introduces binder and solvent as intermediary substances that facilitate the uniform distribution and application of high-concentration phosphor particles. These intermediaries maintain the rheological properties needed for easy coating while allowing high phosphor loading for efficient fluorescence conversion.
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 significantly improves the total efficiency of light-emitting devices by increasing fluorescence and light collection efficiencies, leading to enhanced light emission and reduced surface temperature, thereby improving the overall performance of projectors and light-emitting devices.
Implementation Method 1
a wavelength conversion element having high conversion efficiency from excitation light to fluorescence
Implementation Method 2
a wavelength conversion layer disposed on the substrate and containing a binder and a phosphor
Implementation Method 3
a boiling point of the solvent being in a range of 200° C. to 300° C.
Data Source
AI summary
A wavelength conversion member includes a substrate and a wavelength conversion layer containing a binder and a phosphor and disposed on the substrate. The wavelength conversion layer has a volume ratio of the phosphor to the binder in a range of 0.75 to 1.45 and an average thickness in a range of 55 μm to 146 μm. A method for manufacturing a wavelength conversion member includes applying a phosphor composition onto a substrate, the phosphor composition including a binder, a solvent, and a phosphor, a boiling point of the solvent being in a range of 200° C. to 300° C., a mass ratio of the solvent to the binder being in a range of 0.01 to 0.4, and a mass ratio of the phosphor to the binder being in a range of 3.15 to 6.05, and heat-treating the phosphor composition applied onto the substrate to form a wavelength conversion layer.