Wavelength Converting Module with Planar Base and Intersecting Dividers
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Solution Overview
Problem
Conventional reflective type semiconductor light-emitting apparatuses face issues with heat degradation, leading to decreased light intensity and optical characteristics, especially when using high power semiconductor light sources, and suffer from color variation due to yellow phosphor rings.
Innovation Solution
A reflective type wavelength converting module with a planar base board, intersecting dividers, and a phosphor layer that includes red, green, and blue phosphors, integrated with a heat radiating fin, which prevents color variation and maintains high light intensity by efficiently diffusing light within the phosphor layer without resin components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a high power semiconductor light source is used to increase light intensity, then the light-emitting brightness is improved, but heat generation increases causing degradation of the transparent adhesive material and decrease in reflectivity
Solution Approach 1:
The patent converts the harmful heat generated by high power semiconductor light sources into a beneficial effect by using it to excite the phosphor layer for light emission, while simultaneously implementing heat radiation structures (reflector, base board with heat radiating fins) to manage the thermal load and prevent degradation of adhesive materials and maintain reflectivity
Solution Approach 2:
The patent introduces a base board with high heat radiation efficiency as an intermediary between the semiconductor light source and the phosphor layer, and uses transparent adhesive materials with high heat resistance as mediators to bond components while withstanding thermal stress, thereby preventing degradation and maintaining optical characteristics
2Productivity
If the phosphor layer thickness is increased to improve light conversion efficiency, then the light-emitting efficiency is improved, but color variation such as yellow ring occurs
Solution Approach 1:
The patent applies local quality by creating a non-uniform phosphor layer thickness distribution where the thickness varies from the center to the periphery of the light-emitting surface. Specifically, the phosphor layer is thinner at the periphery and thicker at the center, which compensates for the non-uniform light intensity distribution and prevents color variation such as yellow ring while maintaining high light-emitting efficiency
Solution Approach 2:
The patent changes the physical parameter of phosphor layer thickness to optimize both light-emitting efficiency and color uniformity. By controlling the thickness to be less than the height of the divider and creating a gradient distribution, the patent achieves uniform color tone across the light-emitting surface while preventing color variation
3Temperature
If a metallic reflector is used to radiate heat efficiently, then the heat radiation is improved, but the transparent adhesive material degrades due to heat exposure
Solution Approach 1:
The patent introduces transparent adhesive materials with high heat resistance as intermediaries between the metallic reflector and the phosphor layer. These adhesive materials serve as thermal buffers that protect the bonding interface from excessive heat while maintaining structural integrity and optical transparency
Solution Approach 2:
The patent uses composite material structures including transparent adhesive materials bonded to metallic reflectors with high heat radiation efficiency. The composite structure combines the thermal management capabilities of metal with the optical transparency and heat resistance of specialized adhesive materials, achieving both efficient heat radiation and protection against material degradation
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 enables the emission of uniform color tones with high light intensity, including white light, while effectively radiating heat, thus improving the longevity and performance of semiconductor light-emitting apparatuses for applications like vehicle headlights and general lighting.
Implementation Method 1
a phosphor layer 15 formed on a board top surface 11a of the base board 11 and a divider top surface 17a of the divider 17, the phosphor layer 15 having a thickness lower than a height of the divider 17
Implementation Method 2
a base board 11 formed in a substantially planar shape; a divider 17 located on a board top surface of the base board
Data Source
AI summary
A wavelength converting module and a semiconductor light-emitting apparatus using the wavelength converting module can emit various color lights. The light-emitting apparatus can include a semiconductor light source emitting an exciting light and an optical reflector, which reflects the exciting light toward the wavelength converting module. The wavelength converting module can include a base board and a cavity formed by a divider located on the base board. The exciting light can enter into the cavity including a phosphor layer contained in the wavelength converting module and can emit a mixture light using the phosphor layer in only one cavity. Thus, the semiconductor light-emitting apparatus using the wavelength converting module can emit various color lights having a high light-intensity and a substantially uniform color tone in order to be able to be used for vehicle lamp such as a headlight, general lighting, a stage light, a street light, a projector, etc.