Wavelength Conversion Device Reflective Member
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional color wheels with reflective phosphor powder face challenges in meeting reflective requirements for full incident angles and wavelengths due to the refractive index of the substrate, leading to complex film-coating processes, reliability issues, and increased costs, as well as light absorption due to the Brewster Angle Effect.
Innovation Solution
A wavelength conversion device featuring a substrate with a reflective member composed of a continuous-phase material and dispersively distributed nano particles, where the refractive index of the continuous-phase material differs from that of the nano particles, allowing for reflection of light across full incident angles and wavelengths, similar to a dielectric multi-layer reflective film, while simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric multi-layer reflective film is used to meet reflective requirements for full incident angles and wavelengths, then the reflective performance is improved, but the film-coating process becomes complicated and the cost increases significantly
Solution Approach 1:
The patent uses a composite reflective member consisting of a transparent resin material mixed with transparent particles having different refractive indexes. This composite structure achieves broadband and wide-angle reflection without requiring complex multi-layer dielectric films, thereby simplifying the manufacturing process while maintaining high reflective performance across full incident angles and wavelength spectrums
Solution Approach 2:
The patent changes the refractive index parameter by selecting transparent particles with refractive indexes different from the resin material (e.g., resin with n=1.5 and particles with n=2.0-2.5). By controlling the particle size distribution and concentration, the reflective properties are optimized to achieve full wavelength and angle reflection with a simple single-layer structure
2Ease of manufacture
If a metal reflective layer is used to avoid considering incident angle, then the manufacturing simplicity is improved, but the stability decreases due to oxidation and corrosion
Solution Approach 1:
The patent creates a composite reflective member using transparent resin material combined with transparent particles. This composite provides both the manufacturing simplicity of a single coating layer and the stability of non-metallic materials, eliminating oxidation and corrosion issues while maintaining high reflectivity across all incident angles and wavelengths
Solution Approach 2:
The patent replaces expensive and unstable metal reflective layers with a cost-effective transparent particle composite that offers superior long-term stability. The transparent resin-particle composite is resistant to environmental degradation, providing a durable and economical alternative to metal coatings
3Ease of manufacture
If phosphor powder is coated with glue onto the highly reflective layer, then the coating process is simplified, but light output decreases due to the Brewster Angle Effect causing polarization and penetration of incident light
Solution Approach 1:
Instead of coating phosphor powder with conventional glue onto a separate reflective layer, the patent inverts the approach by mixing transparent particles directly into the resin material to create an integrated reflective-wavelength conversion layer. This eliminates the interface between different materials that causes the Brewster Angle Effect, preventing light polarization and penetration while maintaining coating simplicity
Solution Approach 2:
The patent merges the reflective function and wavelength conversion function into a single integrated layer by mixing transparent particles with phosphor-containing resin material. This unified structure eliminates the need for separate coating layers and interfaces, thereby preventing the Brewster Angle Effect while simplifying the manufacturing process
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 device enhances total output brightness and meets reflective requirements with a simpler process and lower costs by adjusting particle diameter and concentration, achieving improved reflectivity and brightness compared to conventional systems.
Implementation Method 1
A refractive index of the continuous-phase material is different from a refractive index of the nano particles. The reflective member is configured to reflect the light converted from the wavelength conversion member to output.
Implementation Method 2
The reflective member is configured to reflect the light converted from the wavelength conversion member to output.
Implementation Method 3
The nano particles are dispersively distributed in the continuous-phase material. By adjusting the particle diameter and the concentration of the nano particles, a reflection mechanism similar to the conventional dielectric multi-layer reflective film can be achieved
Data Source
AI summary
A wavelength conversion device includes a substrate, a reflective member, and a wavelength conversion member. The reflective member is disposed on the substrate and includes a continuous-phase material and nano particles. The nano particles are distributed in the continuous-phase material. A refractive index of the continuous-phase material is different from a refractive index of the nano particles. The wavelength conversion member is disposed on the reflective member. The reflective member is configured to reflect the light converted from the wavelength conversion member to output.