Wavelength Conversion Module with Anodized Layer for Laser Reliability
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Solution Overview
Problem
Conventional projection devices using phosphor wheels with organic or inorganic adhesives face issues with low resistance to high-power laser irradiation, cracking, and reduced luminous efficiency due to the complexity and pore formation in high-temperature processes, affecting the reliability and optical wavelength conversion efficiency.
Innovation Solution
A wavelength conversion module with an anodized layer having a rough surface is used, where the anodized layer is formed between the substrate and the wavelength conversion layer, allowing for diffuse reflection particles to be embedded, forming a reflective layer without gelatinization, enhancing heat resistance and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If organic adhesive is used to form the reflective layer, then the manufacturing process is simple, but the resistance to high-power laser irradiation is low and cracking occurs
Solution Approach 1:
The patent removes the organic adhesive component from the reflective layer formulation, extracting the problematic element that causes low laser resistance and cracking while retaining the essential reflective functionality through inorganic adhesive and diffuse reflection particles alone
Solution Approach 2:
The patent changes the chemical composition parameters of the reflective layer by substituting organic adhesive with inorganic adhesive, fundamentally altering the material properties to achieve high temperature and laser resistance while maintaining manufacturing feasibility
2Temperature
If inorganic adhesive or glass cement is used to obtain high temperature resistant reflective layer, then heat resistance is improved, but the manufacturing process becomes complicated and substrate strength is degraded
Solution Approach 1:
The patent optimizes the curing temperature parameter to a moderate range (60-150°C), avoiding the high temperature (greater than 400°C) required by conventional inorganic adhesive processes, thereby simplifying the manufacturing process and preserving substrate strength while achieving sufficient heat resistance
Solution Approach 2:
The patent creates a composite reflective layer combining inorganic adhesive with diffuse reflection particles (titanium oxide, aluminum oxide, barium sulfate), achieving high temperature resistance and reflectivity without requiring complex high-temperature processing
3Temperature
If inorganic adhesive or glass cement is used to form reflective layer, then heat resistance is improved, but pores are easily included which reduce reflectance
Solution Approach 1:
The patent adjusts the curing temperature parameter to a moderate range (60-150°C) that prevents pore formation while achieving adequate heat resistance, and optimizes particle concentration (1-10 wt%) to ensure complete filling and high reflectance without voids
Solution Approach 2:
The patent formulates a composite material system where inorganic adhesive and diffuse reflection particles work synergistically, with the adhesive filling gaps between particles to eliminate pores while maintaining high reflectance and heat resistance properties
4Ease of manufacture
If conventional processes are used for reflective substrate, then manufacturing is simplified, but luminous efficiency and reliability are reduced
Solution Approach 1:
The patent develops a composite reflective layer containing inorganic adhesive and diffuse reflection particles in optimized proportions, achieving high reflectance (greater than 90%) and luminous efficiency while maintaining a relatively simple one-step coating and curing process
Solution Approach 2:
The patent optimizes key parameters including particle concentration (1-10 wt%), curing temperature (60-150°C), and layer thickness (1-10 μm) to simultaneously achieve high luminous efficiency and manufacturing simplicity without requiring complex multi-step processes
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 solution improves reflectance, heat resistance, and reliability of the wavelength conversion module, avoiding the risks of organic bonding material deterioration and maintaining good optical quality and conversion efficiency.
Implementation Method 1
the anodized layer has a rough surface... allowing for diffuse reflection particles to be embedded, forming a reflective layer
Implementation Method 2
The anodized layer is located on the substrate, wherein the anodized layer has a rough surface
Data Source
AI summary
A wavelength conversion module, a manufacturing method of wavelength conversion module and a projection device are provided. The wavelength conversion module includes a substrate, an anodized layer and a wavelength conversion layer. The anodized layer is located on the substrate, wherein the anodized layer has a rough surface. The anodized layer is located between the substrate and the wavelength conversion layer, and the rough surface faces the wavelength conversion layer. A projection device having aforesaid wavelength conversion module and a manufacturing method of aforesaid wavelength conversion module are also provided. The wavelength conversion module of the invention has good conversion efficiency and reliability. The projection device of the invention has good optical quality and reliability. The manufacturing method of the wavelength conversion module of the invention can form the wavelength conversion module with good conversion efficiency and reliability.