Wavelength Conversion Module Dual Reflective Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wavelength conversion modules in projection devices face issues with high temperature resistance and reliability due to the deterioration of silicone-based reflective layers, affecting luminous efficiency and color reflection across various wavebands.
Innovation Solution
A wavelength conversion module design featuring a substrate with distinct regions for different reflective layers, where a diffuse reflective layer and a specular reflective layer are positioned to manage heat conduction and reflection efficiently, preventing deterioration and maintaining conversion efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a reflective layer is formed by coating metal films or dielectric films in vacuum, then high temperature resistance and fast heat conduction are achieved, but it is difficult to achieve favorable reflection effect across various color lights simultaneously
Solution Approach 1:
The patent applies different reflective layer structures to different regions of the substrate. The first reflective layer (closer to the wavelength conversion layer) uses metal films or dielectric films for high temperature resistance and fast heat conduction, while the second reflective layer (farther from the wavelength conversion layer) uses diffuse reflection particles for broad spectral reflection. This local differentiation allows each region to optimize for its specific function.
Solution Approach 2:
The reflective function is segmented into two distinct layers: a first reflective layer optimized for thermal management and a second reflective layer optimized for broad spectral reflection. This segmentation allows each layer to be independently optimized for its specific purpose without compromising the other.
2Adaptability or versatility
If a reflective layer is formed by mixing diffuse reflection particles with silicone and coating by printing, spraying or dispensing, then favorable reflection effect across various color lights is achieved, but the silicone may not be resistant to high temperature and is easily deteriorated or burned out
Solution Approach 1:
The patent places diffuse reflection particles in the second reflective layer that is positioned farther from the wavelength conversion layer, where the temperature is lower. This local positioning protects the temperature-sensitive diffuse reflection particles from direct exposure to high temperatures while maintaining their broad spectral reflection capability.
Solution Approach 2:
The first reflective layer acts as an intermediary between the wavelength conversion layer and the second reflective layer. It provides the primary thermal management function and protects the second reflective layer containing temperature-sensitive diffuse reflection particles from direct thermal exposure.
3Ease of manufacture
If the wavelength conversion layer is made of phosphor mixed with silicone, then the structure is simple and easy to manufacture, but the silicone may be deteriorated or burned out after a long time of working, affecting luminous efficiency and reliability
Solution Approach 1:
The patent extracts the wavelength conversion function from the silicone-based reflective layer structure. By separating the wavelength conversion layer (phosphor) from the reflective layers, the system eliminates the fundamental incompatibility between silicone and high-temperature operation, thereby improving reliability while maintaining manufacturing simplicity.
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 module effectively avoids high temperature-induced deterioration, ensuring high conversion efficiency and reliability by using different reflection structures for various energy intensities, thus enhancing the performance of projection devices.
Implementation Method 1
The first reflective layer is disposed on the first region of the substrate, and the first reflective layer is located between the first region of the substrate and the wavelength conversion layer. The second reflective layer is disposed on the second region of the substrate, and the second reflective layer is located between the second region of the substrate and the wavelength conversion layer.
Data Source
AI summary
A wavelength conversion module and a projection device are provided. The wavelength conversion module includes a substrate, a wavelength conversion layer, a first reflective layer, and a second reflective layer. The substrate includes a first region and a second region. The wavelength conversion layer is disposed on the substrate. The first reflective layer is disposed on the first region of the substrate and located between the first region of the substrate and the wavelength conversion layer. The second reflective layer is disposed on the second region of the substrate and located between the second region of the substrate and the wavelength conversion layer, and a distance from a top surface of the second reflective layer to the substrate is shorter than a distance from a top surface of the first reflective layer to the substrate. The projection device includes an illumination system including the wavelength conversion module.