Wavelength Conversion Module Refractive Index Matching
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Solution Overview
Problem
Current phosphor wheels in projection devices face issues with high-temperature degradation and reduced light conversion efficiency due to the use of silicone and inorganic binders, which lead to holes and refractive index mismatches affecting luminous efficiency and reliability.
Innovation Solution
A wavelength conversion module with a substrate, first and second matching material layers, and a filling adhesive channel, where the filling adhesive fills holes in the wavelength conversion layer, enhancing transmittance and conversion efficiency by matching refractive indices and using materials like silicone and epoxy resins with thermal conductive powders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If silicone is used as binder in phosphor wheel, then ease of manufacture is improved, but reliability deteriorates due to high-temperature degradation and burning
Solution Approach 1:
The patent changes the material parameter from silicone to inorganic binder (glass adhesive or ceramic material), which fundamentally alters the thermal stability and high-temperature resistance properties while maintaining the coating process feasibility
Solution Approach 2:
The patent uses composite materials by combining inorganic binder with phosphor particles and reflective materials, creating a phosphor wheel that maintains structural integrity at high temperatures while preserving optical functionality
2Reliability
If inorganic binder is used to replace silicone, then reliability is improved through better thermal conductivity and heat resistance, but manufacturing precision deteriorates due to holes created during sintering or curing molding process
Solution Approach 1:
The patent intentionally creates a porous structure with holes in the wavelength conversion layer that communicate with the external environment, allowing complete discharge of air and volatiles during sintering while maintaining structural integrity
Solution Approach 2:
The patent introduces a matching material layer with refractive index between 1.3 and 1.7 as an intermediary between the phosphor wheel and external environment, which compensates for the refractive index mismatch caused by air holes and improves overall optical performance
3Ease of manufacture
If air holes are present in wavelength conversion layer, then ease of manufacture is improved by allowing volatile discharge, but loss of energy increases due to refractive index mismatch reducing light reception
Solution Approach 1:
The patent designs a porous structure where holes communicate with the external environment, enabling complete discharge of air and volatiles during manufacturing while controlling the pore structure to minimize optical interference
Solution Approach 2:
The matching material layer acts as an optical intermediary that bridges the refractive index gap between air holes (n≈1) and phosphor/glass (n≈1.5), reducing light scattering and improving light reception efficiency
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
Improves the conversion efficiency and optical quality of projection devices by filling holes and optimizing light transmittance through the matching material layers, leading to enhanced performance and reliability.
Implementation Method 1
the filling adhesive channel FC, and the first matching material layer 130 simultaneously have a filling adhesive FM that penetrates to the filling adhesive channel FC formed by a portion of the first holes CA of the wavelength conversion layer 120 via capillary action
Implementation Method 2
a wavelength conversion material WM, and a bonding material BM. The wavelength conversion material WM is dispersed in the bonding material BM
Data Source
AI summary
A wavelength conversion module and a projection device are provided. The wavelength conversion module includes a substrate, a first matching material layer, a wavelength conversion layer, a second matching material layer, and a filling adhesive channel. The first matching material layer is located on the substrate. The wavelength conversion layer is located between the substrate and the first matching material layer, and the wavelength conversion layer includes a plurality of first holes, a wavelength conversion material, and a bonding material. The wavelength conversion material is dispersed in the bonding material. The second matching material layer is located between the substrate and the wavelength conversion layer. The filling adhesive channel is connected to the first matching material layer and the second matching material layer, and the second matching material layer, the filling adhesive channel, and the first matching material layer have a filling adhesive with the same material.