Wavelength-Converting Element with Multi-Size Phosphors
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Solution Overview
Problem
Conventional wavelength-converting elements face challenges in achieving high wavelength converting efficiency due to single particle size phosphors, which affect adhesion properties and light converting efficiency, and using carrier boards with mirror reflection can reduce adhesion force.
Innovation Solution
A wavelength-converting element with a substrate, optical film, and fluorescent film containing phosphors of multiple particle sizes, where larger phosphors are distributed to match the power density distribution of the excitation beam, enhancing wavelength converting efficiency and adhesion force through a substrate with a rough surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the concentration of phosphors is increased to enhance converting efficiency, then wavelength converting efficiency is improved, but adhesion properties of the phosphor layer deteriorate
Solution Approach 1:
The patent applies local quality by using phosphors with different particle sizes in different regions of the wavelength-converting layer. Larger phosphors (first particle size) are used in the central region where excitation beam intensity is highest, while smaller phosphors (second particle size) are used in the peripheral region. This regional differentiation optimizes both converting efficiency in high-intensity areas and adhesion properties in low-intensity areas, resolving the contradiction between efficiency and adhesion.
2Loss of energy
If a carrier board with mirror reflection effect is used to improve reflection efficiency, then overall reflection efficiency is improved, but adhesion force between phosphor layer and carrier board deteriorates
Solution Approach 1:
The patent changes the surface roughness parameter of the carrier board from smooth (mirror-like) to rough. This parameter change enables the carrier board to provide both good adhesion force for the phosphor layer and effective light reflection, resolving the contradiction between reflection efficiency and adhesion force.
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 effectively enhances wavelength converting efficiency and reliability by matching phosphor particle sizes with excitation beam intensity and improving adhesion, while reducing material costs and maintaining product reliability.
Implementation Method 1
the fluorescent film is configured to convert the excitation beam into a converting beam
Data Source
AI summary
A projector and a wavelength-converting element are disclosed. The projector includes an illumination system, a light valve and a lens. The illumination system includes a light source providing an excitation beam, and a wavelength conversion device located at a transmission path of the excitation beam. The wavelength-converting element includes a substrate having a wavelength-converting area, an optical film disposed in the wavelength-converting area of the substrate, and a fluorescent film covering the optical film and converts the excitation beam into a converting beam. The converting beam and the excitation beam constitute an illumination beam. The fluorescent film contains phosphors, wherein the phosphors having a larger particle size are distributed among or above the phosphors having a smaller particle size. The light valve converts the illumination beam into an image beam. The image beam becomes a projection beam after passing through the lens.