Wavelength Conversion Module with Colloidal Bosses for Heat Dissipation
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Solution Overview
Problem
Current phosphor wheels face challenges with heat dissipation due to the limitations of metal and ceramic substrates, where metal substrates cannot withstand high sintering temperatures and ceramic substrates are brittle, leading to poor heat dissipation and reliability issues.
Innovation Solution
A wavelength conversion module featuring a ceramic substrate with colloidal bosses that are heat-resistant above 500 degrees Celsius, separated from the wavelength conversion layer, enhancing heat dissipation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal heat dissipation substrates are used for phosphor wheels, then heat dissipation efficiency is improved through high thermal conductivity, but the substrate cannot withstand high sintering temperatures (above 500 degrees Celsius) required for bonding phosphor layers
Solution Approach 1:
The patent uses a composite structure combining metal heat dissipation substrate with ceramic coating layer. The metal substrate provides high thermal conductivity for heat dissipation, while the ceramic coating layer provides high-temperature resistance to withstand sintering temperatures above 500 degrees Celsius. This composite approach resolves the contradiction between heat dissipation efficiency and temperature resistance.
2Reliability
If ceramic substrates are used for phosphor wheels to withstand high sintering temperatures, then temperature tolerance is improved (greater than 600 degrees Celsius), but the substrate is brittle and forms hidden cracks during processing and operation
Solution Approach 1:
The patent combines ceramic coating layer with metal substrate to create a composite structure. The metal substrate provides mechanical strength and toughness to prevent cracking, while the ceramic coating layer provides high-temperature tolerance greater than 600 degrees Celsius. This resolves the contradiction between temperature tolerance and mechanical strength.
Solution Approach 2:
The patent applies ceramic coating only on the surface of the metal substrate where high-temperature resistance is needed, while the bulk metal substrate maintains its mechanical strength properties. This local application of ceramic coating provides temperature tolerance at the critical surface region without compromising the overall structural strength.
3Temperature
If boss structures are formed on ceramic substrate surfaces to enhance heat dissipation, then heat dissipation efficiency is improved through increased surface area and turbulence, but the boss structures cannot be formed on ceramic substrates due to material properties
Solution Approach 1:
The patent uses metal substrate with ceramic coating, where the metal substrate allows formation of boss structures through stamping or processing methods. The metal material properties enable easy formation of surface structures like bosses that enhance heat dissipation, while the ceramic coating provides the necessary high-temperature resistance. This resolves the contradiction between heat dissipation efficiency and ease of manufacture.
4Strength
If inorganic sealants are used to sinter phosphor powders on heat dissipation substrates, then bonding strength is improved, but the sintering temperature must be higher than 500 degrees Celsius which metal substrates cannot withstand
Solution Approach 1:
The patent uses ceramic coating layer on metal substrate that can withstand high sintering temperatures above 500 degrees Celsius. The ceramic material allows use of high-temperature inorganic sealants for strong bonding of phosphor powders, while the underlying metal substrate provides heat dissipation capability. This resolves the contradiction between bonding strength and sintering temperature tolerance.
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 design improves heat dissipation efficiency, increases excitation efficiency, and enhances the reliability and toughness of the wavelength conversion module, while maintaining high-temperature stability without contaminating optical lenses.
Implementation Method 1
The colloidal bosses generate turbulence or enhance convection during the high-speed rotation of the phosphor wheels, and accelerate the removal of the heat around the phosphor wheels through the turbulence or convection
Implementation Method 2
These boss structures generate turbulence or enhance convection during the high-speed rotation of the phosphor wheels
Implementation Method 3
a ceramic substrate with high thermal conductivity is also used currently as the heat dissipation substrate
Implementation Method 4
The wavelength conversion module is disposed on a transmission path of the excitation beam and is configured to convert the excitation beam into a conversion beam
Data Source
AI summary
A wavelength conversion module includes a ceramic substrate, a wavelength conversion layer, and a plurality of colloidal bosses. The ceramic substrate has a first surface. The wavelength conversion layer is disposed on the first surface of the ceramic substrate. The colloidal bosses are separately from each other disposed on the ceramic substrate and at least located on the first surface. The colloidal bosses and the wavelength conversion layer are separated from each other, and a heat resistant temperature of the colloidal bosses is higher than 500 degrees. The above wavelength conversion module has favorable heat dissipation effect.