Wavelength Conversion Element Partial Binder Binding
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Solution Overview
Problem
Existing wavelength conversion elements suffer from reduced efficiency due to the spread of fluorescence within the binder, leading to decreased incident efficiency in optical systems, as the binder covers the entire surface of phosphor particles, increasing the exit area of fluorescence compared to the incident excitation light area.
Innovation Solution
A wavelength conversion element with a phosphor layer where the binder, composed of glass, binds only a part of the surface of each phosphor particle, limiting the binder's volume to no more than 10% of the total volume, and a calcination process with a temperature above the glass's softening point to control the binder's viscosity and binding area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the binder covers the entire surface of phosphor particles, then the phosphor particles are well bound together, but the exit area of fluorescence increases and incident efficiency to the optical system decreases
Solution Approach 1:
The binder is applied selectively to only specific regions of the phosphor particle surface rather than covering the entire surface. This local application ensures sufficient binding between particles while minimizing the area where fluorescence is trapped and re-emitted, thereby maintaining binding strength while improving incident efficiency to the optical system.
2Strength
If the binder volume is increased to ensure complete coverage, then binding is improved, but fluorescence spread increases and optical system efficiency decreases
Solution Approach 1:
Instead of applying binder in excessive amounts to achieve complete coverage, the invention uses partial coverage with optimized binder volume. The binder volume is controlled to be sufficient for binding purposes but not excessive enough to cause significant fluorescence spread, thus achieving binding strength without compromising optical system efficiency.
3Ease of manufacture
If the calcination temperature is increased to control binder viscosity, then the binder spreads more and covers more phosphor particle surface, but fluorescence spread increases
Solution Approach 1:
The calcination temperature is precisely controlled within a specific range to achieve optimal binder viscosity. By adjusting this parameter, the binder has just enough fluidity to spread and bind particles effectively, but not so much that it excessively covers the phosphor particle surface and causes fluorescence spread, thus maintaining incident 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
This configuration reduces the spread of fluorescence, enhancing the brightness and optical system efficiency by minimizing the area of the binder on the phosphor particles, thereby improving light collection and reducing self-absorption.
Implementation Method 1
the binder includes glass, and the binder binds a part of a surface of the one of the phosphor particles and a part of a surface of the another of the phosphor particles to each other
Implementation Method 2
a calcination process with a temperature above the glass's softening point to control the binder's viscosity and binding area
Implementation Method 3
a phosphor layer having a plurality of phosphor particles... each a phosphor shaped like a particle which absorbs the excitation light emitted from the outside to emit the fluorescence
Data Source
AI summary
The wavelength conversion element includes a phosphor layer having a plurality of phosphor particles and a binder configured to bind one of the phosphor particles adjacent to each other and another of the phosphor particles adjacent to each other out of the plurality of phosphor particles, and a substrate provided with the phosphor layer, wherein the binder includes glass, and the binder binds a part of a surface of the one of the phosphor particles and a part of a surface of the another of the phosphor particles to each other.