Wavelength-Converting Element Using Inorganic Binder
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Solution Overview
Problem
Conventional phosphor wheels in high-power laser projection apparatuses face issues with thermal conductivity, temperature resistance, and reflectivity due to the use of highly transparent silica gel, leading to image brightness degradation and high costs for red and green laser diodes.
Innovation Solution
A wavelength-converting element with a substrate and a wavelength-converting layer using a first inorganic binder, such as an alcohol-soluble or water-soluble binder, which improves temperature resistance and energy tolerance by reducing curing temperatures and eliminating the need for intermediate layers, allowing direct coating and enhancing reflectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If highly transparent silica gel is used as the binder in the phosphor powder layer, then the material provides good transparency, but the thermal conductivity is poor and temperature resistance is low
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by replacing organic silica gel with inorganic binders (water glass, colloidal silica, or alumina sol). This fundamental material substitution transforms the thermal properties while maintaining optical transparency, allowing the binder to withstand temperatures up to 400-600°C while preserving light transmission characteristics.
Solution Approach 2:
The patent creates a composite binder system by combining inorganic binder materials with phosphor particles. This composite structure integrates the thermal stability of inorganic materials with the optical conversion properties of phosphor, achieving both high temperature resistance and transparency simultaneously.
2Strength
If the diffuse reflection material is cured at high temperature (>400°C) to form a diffuse reflection layer, then the layer is formed, but the cured layer has more pores which decreases reflectivity
Solution Approach 1:
The patent changes the curing temperature parameter from high temperature (>400°C) to low temperature (room temperature or slightly elevated). This parameter modification prevents excessive pore formation during curing while still achieving complete polymerization and layer formation, thereby maintaining high reflectivity without sacrificing structural integrity.
Solution Approach 2:
The patent replaces high-temperature thermal curing with chemical curing mechanisms that operate at lower temperatures. By using binders that can cure at room temperature or low temperatures, the process avoids thermal pore formation while achieving equivalent or superior layer consolidation through chemical cross-linking reactions.
3Device complexity
If conventional phosphor wheel materials are used, then the structure is simple, but the energy tolerance is insufficient for high-power laser projection
Solution Approach 1:
The patent develops composite phosphor layer formulations by combining inorganic binder materials with phosphor particles in specific ratios. This composite approach enhances energy tolerance and thermal stability while maintaining the fundamental phosphor wheel structure, allowing the system to handle high-power laser inputs without fundamental redesign.
Solution Approach 2:
The patent modifies the compositional parameters of the phosphor layer by adjusting the ratio of inorganic binder to phosphor particles, optimizing the layer for high energy tolerance. This parameter optimization enables the conventional phosphor wheel structure to withstand high-power laser projection applications.
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 solution improves image brightness, reduces the risk of substrate deformation and film failure, and extends the temperature resistance of the wavelength-converting layer to 400° C. to 600° C., enabling its use in high-power projection systems while lowering costs.
Implementation Method 1
a blue laser diode is used to excite the phosphor on the phosphor wheel to generate yellow light and green light
Implementation Method 2
The first inorganic binder includes a first alcohol-soluble inorganic binder or a first water-soluble inorganic binder
Data Source
AI summary
A wavelength-converting element includes a substrate and a wavelength-converting layer. The wavelength-converting layer is disposed on the substrate. The wavelength-converting layer includes a first inorganic binder and a wavelength-converting material. The wavelength-converting material is mixed with the first inorganic binder. The first inorganic binder includes a first alcohol-soluble inorganic binder or a first water-soluble inorganic binder. A projection apparatus using the wavelength-converting element and a manufacturing method of the wavelength-converting element are also provided.