Wavelength Converting Member Indentation Design for Heat Management
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Solution Overview
Problem
Conventional wavelength converting devices with phosphor wheels face challenges in achieving high light emission efficiency while maintaining a compact size and reducing manufacturing costs, as they often require additional cooling components that increase size and complexity, and simple cooling methods fail to adequately manage heat, affecting phosphor performance.
Innovation Solution
A wavelength converting member with a disc-shaped substrate featuring multiple phosphor regions, where each region employs a two-stage wavelength conversion process with phosphors arranged in a specific configuration, including indentations in one phosphor layer to enhance light absorption and emission efficiency, reducing heat generation and allowing for a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the intensity of light irradiated on the phosphors is increased to achieve higher output, then the light emission efficiency is improved, but the heat generated by the phosphors increases, which reduces the wavelength converting efficiency
Solution Approach 1:
The phosphor wheel is divided into multiple wavelength converting regions arranged in the circumferential direction, with each region containing phosphors of different types. This segmentation allows different phosphor materials to be optimized for specific wavelength conversions while distributing heat generation across multiple zones rather than concentrating it in a single region.
Solution Approach 2:
Different phosphor materials with specific characteristics are placed in different circumferential regions of the wheel. Each phosphor layer is positioned to convert specific wavelengths, creating local optimization where each region's phosphor properties are matched to its specific conversion function, improving overall efficiency while managing heat distribution.
2Temperature
If additional cooling components such as cooling fans or air blowers are added to cool the phosphor wheel, then the phosphor temperature is controlled, but the device size and manufacturing costs increase
Solution Approach 1:
The wavelength converting member itself serves the dual function of both converting wavelengths and managing its own thermal characteristics. By incorporating thermally conductive substrates and designing the phosphor layer configurations to facilitate heat dissipation, the system achieves passive thermal management without requiring external cooling fans or air blowers, thereby reducing device complexity and manufacturing costs.
3Volume of moving object
If the size of the phosphor wheel is reduced to achieve a more compact projector, then the device size is decreased, but the light emission efficiency of the phosphors becomes insufficient
Solution Approach 1:
The invention transitions from a single-layer phosphor structure to a multi-layer circumferential arrangement. By organizing phosphor layers in the circumferential dimension of the rotating wheel, the system maximizes the light conversion path length and surface area within a compact radial footprint, thereby maintaining high light emission efficiency while achieving a reduced overall device size.
Solution Approach 2:
Multiple types of phosphor materials are combined in a composite wheel structure with different phosphor layers positioned circumferentially. This composite approach allows simultaneous optimization of different wavelength conversions within a single compact component, achieving sufficient light emission efficiency across multiple spectral regions without increasing the overall wheel size.
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 configuration improves wavelength conversion efficiency by reducing heat buildup and allowing for a more compact and cost-effective projector design, while maintaining sufficient light emission efficiency.
Implementation Method 1
The first phosphor layer contains a first phosphor absorbing at least part of incident light and emitting first light which is different in wavelength from the incident light
Implementation Method 2
The second phosphor layer contains a second phosphor absorbing at least part of the first light emitted by the first phosphor and emitting second light which is different in wavelength from the first light
Implementation Method 3
The third phosphor layer containing a third phosphor absorbing at least part of incident light and emitting third light which is different in wavelength from the incident light
Data Source
AI summary
A wavelength converting member includes at least a first, second, and third regions, circumferentially on a disc-shaped light-transmissive substrate. The first region includes, from a light incident direction, a first and second phosphor layers. The first phosphor layer includes a first phosphor to absorb at least part of incident light and to emit a first light having a wavelength different from the incident light. The first phosphor layer defines an indentation in a surface on the second phosphor layer side, with a depth a half or more of the thickness of a portion of the first phosphor layer absent of the indentation. The second phosphor layer includes a second phosphor to absorb at least part of the first light emitted by the first phosphor and to emit a second light having a wavelength different from the first light, and is disposed in the indentation of the first phosphor layer.