Wavelength Conversion Module With Polymer Adhesive Ring Assembly

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Solution Overview

Problem

The existing wavelength conversion modules in projectors face issues with poor adhesion stability due to large thermal expansion coefficient differences between balance weights and metal balance weight rings, leading to potential detachment during high-speed rotation, and require multiple adhesive layers complicating the manufacturing process and increasing costs.

Innovation Solution

A wavelength conversion module featuring a polymer adhesive ring disposed on a wavelength conversion substrate, manufactured using a mold, which enhances adhesion stability and allows for simplified assembly by omitting additional adhesive layers, utilizing materials like silicon or epoxy resin adhesives with optional filling particles for increased strength and rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal balance weight ring is used with balance weights, then dynamic balance calibration can be achieved, but adhesion stability deteriorates due to large thermal expansion coefficient differences causing balance weights to fly away during high-speed rotation

Engineering Contradiction:

Improveadhesion stabilityVSAvoidthermal expansion coefficient difference

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter of the balance weight ring from metal to polymer, which has a smaller thermal expansion coefficient that better matches the balance weight material. This parameter change resolves the thermal expansion mismatch problem that caused adhesion failure during high-speed rotation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining polymer adhesive ring with filling particles (such as metal particles, ceramic particles, or glass particles) to create a balance weight ring that has both good adhesion properties and appropriate mechanical strength, while maintaining compatible thermal expansion characteristics.

Inventive Principle:

Principle #40Composite materials

2Reliability

If multiple adhesive layers are used to assemble the phosphor wheel, then structural integrity is maintained, but manufacturing complexity increases and production cost rises

Engineering Contradiction:

Improvestructural integrityVSAvoidnumber of adhesive layers

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple adhesive layers into a single integrated polymer adhesive ring structure. This single component performs the functions of multiple separate adhesive layers, simplifying the assembly process while maintaining structural integrity through the ring's continuous circumferential configuration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The polymer adhesive ring serves multiple functions simultaneously: it provides adhesion, structural support, and acts as a balance weight ring. This multi-functional design eliminates the need for separate adhesive layers and metal balance weight rings, reducing manufacturing complexity while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If multiple adhesive layers and metal balance weight ring assembly are used, then assembly is achievable, but production time and cost increase

Engineering Contradiction:

Improveassembly feasibilityVSAvoidproduction time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent segments the manufacturing process by providing the polymer adhesive ring as a pre-formed component that can be directly installed onto the substrate. This segmentation eliminates the need for complex multi-step assembly operations involving multiple adhesive layers and separate balance weight ring assembly, thereby reducing production time while maintaining assembly feasibility.

Inventive Principle:

Principle #1Segmentation

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 polymer adhesive ring provides improved adhesion stability and reduces manufacturing complexity and costs by simplifying the assembly process, ensuring better structural reliability and reduced production time.

Implementation Method 1

a polymer adhesive ring is disposed on the wavelength conversion substrate

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the polymer adhesive ring is mixed with a plurality of filling particles, and the filling particles include a plurality of polymer particles, a plurality of glass particles, a plurality of ceramic particles, a plurality of metal particles

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Data Source

PatentUS12560801B2Wavelength conversion module and manufacturing method thereof

Publication Date: 2026.02.24 CORETRONIC CORPORATION

AI summary

A wavelength conversion module and a manufacturing method thereof are provided. The wavelength conversion module includes a wavelength conversion substrate, a driving assembly, and a polymer adhesive ring. The driving assembly is connected to the wavelength conversion substrate to drive the wavelength conversion substrate to rotate around an axis of the driving assembly. The polymer adhesive ring is disposed on the wavelength conversion substrate.