Wavelength Conversion Member Surface Recesses for Light Confinement
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Solution Overview
Problem
Existing wavelength conversion members face challenges in improving light confinement on surfaces other than the light incidence and emission faces, leading to inefficient light conversion and leakage.
Innovation Solution
A method of manufacturing a wavelength conversion member by creating a sintered body with recessed portions on its light reflecting face through acid treatment, which reduces the exposure of phosphor particles and enhances light confinement by forming a refractive index difference with inorganic particles and air in the recessed areas, and optionally using a reflecting member to cover the sintered body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a sintered body is used as a wavelength conversion member, then wavelength conversion function is achieved, but light confinement on surfaces other than light incidence and emission faces is insufficient
Solution Approach 1:
The patent applies local quality by creating recessed portions only on specific surfaces (light reflecting faces) of the sintered body, while leaving other surfaces (light incidence and emission faces) unchanged. This localized surface treatment improves light confinement precisely where needed without affecting the optical performance of the light transmission faces.
Solution Approach 2:
The patent employs preliminary action by performing acid treatment on the sintered body before final assembly or use. The recessed portions are formed in advance through acid etching, which removes phosphor particles from the surface to create the light-confining structure, preparing the surface for optimal optical performance before the device is put into service.
2Loss of energy
If phosphor particles are dispersed in an alumina ceramic matrix, then wavelength conversion is enabled, but light confinement property on lateral surfaces is poor
Solution Approach 1:
The patent replaces mechanical surface treatment methods with chemical etching using acid. Instead of mechanically removing phosphor particles or creating surface structures through machining, the invention uses acid to chemically etch the alumina ceramic matrix, selectively removing phosphor particles and creating recessed portions through chemical reactions.
Solution Approach 2:
The patent utilizes the porous nature created by acid etching to improve light confinement. The acid treatment creates a porous surface structure with recessed portions that trap light through multiple internal reflections, preventing light leakage from lateral surfaces while maintaining the bulk optical conversion functionality.
3Loss of energy
If surface(s) other than light incidence and emission faces are covered with a reflecting member, then light confinement is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the wavelength conversion function and the light confinement function into a single integrated component. By forming recessed portions directly on the sintered body surface, the invention eliminates the need for separate reflecting member components, combining what would have been distinct elements (wavelength converter + reflector) into one unified structure.
Solution Approach 2:
The sintered body itself provides the light confinement function through its own modified surface structure. The recessed portions created by acid treatment enable the wavelength conversion member to confine light internally through total internal reflection at the recessed surfaces, making the component self-sufficient and eliminating dependence on external reflecting members.
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 method effectively improves light confinement on the reflecting face, reducing light leakage and enhancing the luminance difference between the emission face and the surrounding area, resulting in improved wavelength conversion efficiency and a clearly distinguishable light-dark boundary.
Implementation Method 1
forming a plurality of recessed portions on the light reflecting face of the sintered body, which comprises acid treating the sintered body
Implementation Method 2
enhances light confinement by forming a refractive index difference with inorganic particles and air in the recessed areas
Data Source
AI summary
A method of manufacturing a wavelength conversion member that includes a sintered body having a light incidence face, a light emission face, and a light reflecting face different from the light incidence face and the light emission face, the method comprising: providing a sintered body containing inorganic particles and phosphor particles, and forming a plurality of recessed portions on the light reflecting face of the sintered body, which comprises acid treating the sintered body.