Wavelength Conversion Device Pore Filling for Optical Yield
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Solution Overview
Problem
Current wavelength conversion devices in projection systems face challenges with pores in phosphor particles, leading to decreased optical effects and complex, costly manufacturing processes, as high-temperature sintering is required to resolve pores but is not feasible due to heat limitations in substrates.
Innovation Solution
A wavelength conversion device with a substrate and a wavelength conversion layer having pores on its surface, filled with a transparent filling layer that has a transmittance of at least 85% for visible light, which improves optical effects without requiring high-temperature processing, simplifying the manufacturing process and enhancing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature sintering is performed to resolve pores in phosphor particles, then optical effects are improved, but manufacturing process becomes complicated and costly, and substrate cannot withstand the temperature
Solution Approach 1:
The patent divides the pore-filling process into two stages: first forming the wavelength conversion layer with pores through conventional low-temperature sintering, then separately filling the pores with transparent resin material. This segmentation allows each stage to use appropriate processing conditions without requiring high-temperature sintering of the entire structure.
Solution Approach 2:
The patent performs preliminary action by forming the wavelength conversion layer with pores before filling them. The porous structure is intentionally created and then filled with transparent resin, which prevents pore formation issues while avoiding the need for high-temperature processing that the substrate cannot withstand.
2Reliability
If additional layer of glass or ceramic is sintered to resolve pores, then pore problem is resolved, but manufacturing process becomes complicated and costly
Solution Approach 1:
The patent changes the filling material from traditional glass or ceramic requiring high-temperature sintering to transparent resin material that can be filled at low temperatures. This parameter change in material selection resolves the pore issue while keeping the manufacturing process simple and cost-effective.
Solution Approach 2:
The patent uses transparent resin material instead of expensive glass or ceramic layers. The resin provides the necessary pore-filling function at lower cost and with simpler processing, making the manufacturing process more economical and easier to implement.
3Temperature
If alcohol-soluble or water-soluble low-temperature inorganic adhesive is used, then heat-dissipating substrate can be used, but high-temperature sintering cannot be performed
Solution Approach 1:
The patent creates a composite structure combining the wavelength conversion layer with transparent resin filling material. This composite approach allows the use of low-temperature processing compatible with heat-dissipating substrates while the resin filling effectively resolves the pore formation issue that would otherwise require high-temperature sintering.
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 filling layer effectively fills pores in the wavelength conversion layer, improving optical effects and simplifying the manufacturing process while reducing costs, and when combined with an anti-reflection layer, further enhances luminance in projection devices.
Implementation Method 1
The filling layer is disposed on the surface of the wavelength conversion layer to fill the pores
Implementation Method 2
a blue LD to emit an excitation light beam to a phosphor color wheel, where the excitation light beam excites phosphor powder of the phosphor color wheel to generate yellow green light
Data Source
AI summary
A wavelength conversion device includes a substrate, a wavelength conversion layer and a filling layer. The wavelength conversion layer is disposed on the substrate. A surface of the wavelength conversion layer away from the substrate has a plurality of pores, the filling layer is disposed on the surface of the wavelength conversion layer to fill the pores, where the filling layer is a transparent structure, and a transmittance of the filling layer to visible light is greater than or equal to 85%. A projection device having the above wavelength conversion device is also provided. The wavelength conversion device and the projection device of the invention may simplify a manufacturing process to save costs, and a yield and optical effects thereof are improved.