Wavelength Converting Member Passive Capillary Cooling

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Solution Overview

Problem

Existing light source devices using semiconductor lasers or LEDs with fluorescent materials face challenges in miniaturization and increased energy consumption due to the need for a circulation channel and pump to cool the fluorescent materials, leading to inefficiencies in light conversion efficiency.

Innovation Solution

A wavelength converting member with a sealed, light-transmissive housing containing a coolant and micro-passages formed by gaps between particles, where the coolant flows by capillary action to cool phosphor particles without a driving source, utilizing natural convection and heat vaporization to maintain efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a circulation channel and pump are used to cool the fluorescent material, then the light converting efficiency is maintained, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvelight converting efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and removes the pump component from the cooling system. Instead of using an active pump-driven circulation channel, the invention uses passive capillary channels formed by porous material that automatically transport coolant through capillary action, eliminating the need for mechanical pumping while maintaining cooling effectiveness.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The cooling system is designed to be self-service through capillary action. The porous material inherently provides the driving force for coolant circulation without external energy input. The system uses its own structural properties (capillary channels) to achieve automatic coolant flow, making the system self-regulating and eliminating complex control mechanisms.

Inventive Principle:

Principle #25Self-service

2Reliability

If a circulation channel and pump are used to cool the fluorescent material, then the light converting efficiency is maintained, but the energy consumption increases

Engineering Contradiction:

Improvelight converting efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the mechanical pump system with a physical phenomenon-based system. Instead of using mechanical energy to drive coolant circulation, the invention utilizes capillary action—a surface tension phenomenon—to automatically transport the coolant through the porous material, thereby eliminating the energy consumption associated with mechanical pumping.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #25Self-service

3Reliability

If a circulation channel and pump are used to cool the fluorescent material, then the light converting efficiency is maintained, but the device size increases

Engineering Contradiction:

Improvelight converting efficiencyVSAvoiddevice size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent employs a thin porous layer as the cooling structure. This porous material can be made as a thin film or coating that integrates directly with the fluorescent material substrate, eliminating the need for bulky three-dimensional circulation channels and pump housing, thereby significantly reducing the overall device volume.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The cooling function is merged with the fluorescent material structure itself. The porous cooling channels are formed within or as part of the fluorescent material layer, combining the light-converting and cooling functions in a single integrated component, which reduces the total device size compared to separate cooling system components.

Inventive Principle:

Principle #5Merging (Combining)

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

This solution enables efficient cooling of fluorescent materials without a driving source, reducing energy consumption and maintaining light conversion efficiency, while allowing for miniaturization and lower manufacturing costs.

Implementation Method 1

a channel arranged in the sealed housing and having a plurality of micro-passages allowing a liquid coolant flowing therein. At least a portion of the micro-passages are formed by gaps between particles

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

utilizing natural convection and heat vaporization to maintain efficiency

Methodology Applied

Scientific EffectHeat vaporization: Evaporation

Implementation Method 3

utilizing natural convection and heat vaporization to maintain efficiency

Methodology Applied

Scientific EffectNatural convection: Free Convection

Data Source

PatentUS9982867B2Wavelength converting member and light source device having the wavelength converting member

Publication Date: 2018.05.29 NICHIA CORP

AI summary

A wavelength converting member includes a sealed housing which is at least partially light transmissive, a coolant enclosed in the sealed housing, a cooling part provided on a part of an external surface of the sealed housing, and a channel having a plurality of micro-passages allowing a liquid coolant flowing therein. At least a portion of the micro-passages are formed by gaps between particles, and phosphor particles are contained in the particles.