Wavelength-Converting Element Inorganic Binder Thermal Management
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Solution Overview
Problem
Conventional phosphor wheels in high-power laser projection apparatuses face issues with thermal conductivity and reflectivity due to the use of highly transparent silica gel, which requires high curing temperatures and results in porous diffuse reflection layers, leading to decreased brightness and color saturation.
Innovation Solution
A wavelength-converting element is manufactured using a diffuse reflection layer with an inorganic binder and diffuse reflection particles, where the inorganic binder includes an alcohol-soluble or water-soluble component, allowing for a lower curing temperature of 200° C. to 300° C., reducing pore formation and improving reflectivity, and an intermediate layer is added for thermal conductivity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If highly transparent silica gel is used as the binder in the diffuse reflection layer, then the material achieves 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 or supplementing silica gel with inorganic binder materials that have different thermal properties, thereby improving thermal conductivity while maintaining transparency
Solution Approach 2:
The patent creates a composite binder system combining silica gel with inorganic binder materials, achieving a balance between transparency and thermal conductivity through material composition optimization
2Stability of the object's composition
If the diffuse reflection layer is cured at high temperature (>400°C), then the material forms a stable structure, but the diffuse reflection layer develops more pores which decreases reflectivity
Solution Approach 1:
The patent changes the curing temperature parameter from high temperature (>400°C) to lower temperature ranges, preventing excessive pore formation while achieving sufficient structural stability through modified binder chemistry
Solution Approach 2:
The patent optimizes the local properties of the binder material to enable curing at lower temperatures while maintaining structural stability, using inorganic binder materials with appropriate glass transition temperatures
3Ease of manufacture
If conventional phosphor wheel materials are used, then the manufacturing process is simple, but the brightness and color saturation of the projected image decrease
Solution Approach 1:
The patent uses composite materials including inorganic binder materials, phosphor particles, and diffuse reflection particles in specific ratios to enhance brightness and color saturation while maintaining manufacturing feasibility
Solution Approach 2:
The patent optimizes parameters such as particle size distribution, material composition ratios, and curing conditions to improve optical performance while keeping the manufacturing process practical
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 improved wavelength-converting element enhances image brightness by increasing reflectivity and reducing thermal issues, allowing for more efficient light utilization and better heat dissipation, thereby addressing the limitations of conventional phosphor wheels.
Implementation Method 1
the inorganic binder has a hydroxyl group
Implementation Method 2
a material of the intermediate layer comprises a silica gel, an epoxy resin or a thermal conductive adhesive
Implementation Method 3
the diffuse reflection layer includes an inorganic binder and a plurality of diffuse reflection particles
Data Source
AI summary
A wavelength-converting element includes a substrate, a wavelength-converting layer and a diffuse reflection layer. The wavelength-converting layer is disposed above the substrate. The diffuse reflection layer is disposed between the substrate and the wavelength-converting layer. The diffuse reflection layer includes an inorganic binder and a plurality of diffuse reflection particles. The diffuse reflection particles are mixed with the inorganic binder. The inorganic binder includes an alcohol-soluble inorganic binder or a water-soluble inorganic binder. A projection apparatus using the wavelength-converting element and a manufacturing method of the wavelength-converting element are also provided.