Wavelength Conversion Wheel Segment Layout for Shorter Cutting Paths
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Solution Overview
Problem
The manufacturing cost and production efficiency of wavelength conversion wheels using sintered-type wavelength conversion elements are hindered by the arrangement of segments on a plate-shaped sintered substrate and the cutting distance required to separate individual segments.
Innovation Solution
The wavelength conversion wheel is designed with segments defined by inner and outer arc edges, where the outer arc edge includes a first arcuate section matching the inner arc edge in shape and arc length, and arranged such that concave sides face inward, allowing for common breaking lines in cutting, reducing the cutting distance and improving production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segments are arranged on a plate-shaped sintered substrate for manufacturing wavelength conversion wheels, then the wavelength conversion elements can be produced, but the cutting distance required to separate individual segments increases, reducing production efficiency
Solution Approach 1:
The wavelength conversion element is divided into multiple segments that are arranged on the plate-shaped sintered substrate. Each segment corresponds to a specific wavelength conversion region, allowing for modular manufacturing and efficient separation along predetermined breaking lines.
Solution Approach 2:
The segments are pre-arranged on the plate-shaped sintered substrate in a specific configuration before the cutting process. The breaking lines are predetermined and pre-marked, allowing for rapid and accurate separation of individual wavelength conversion elements without requiring complex real-time positioning during cutting.
2Productivity
If the cutting distance is reduced to improve production efficiency, then more segments can be produced per unit time, but the arrangement of segments on the substrate becomes more complex
Solution Approach 1:
The plate-shaped sintered substrate serves multiple functions: it acts as the base structure for mounting segments, provides predetermined breaking lines for separation, and enables efficient cutting paths. This multi-functional design simplifies the overall manufacturing process despite the complex segment arrangement.
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 enables efficient separation of segments with reduced cutting distance, enhancing production efficiency and yield, and allows for flexible production of segments with varying sizes on a single substrate.
Implementation Method 1
a wavelength conversion material that is capable of converting incident light to light of a wavelength different from the wavelength of the incident light
Data Source
AI summary
A wavelength conversion wheel according to the present disclosure includes: a base plate rotatable around an axis; and at least one wavelength conversion element arranged on the base plate and the wavelength conversion element including a wavelength conversion material that is capable of converting incident light to light of a different wavelength. The wavelength conversion element includes at least one segment, the segment is defined by an inner arc edge, an outer arc edge, and both side edges each connecting two corresponding end points of the inner arc edge and the outer arc edge, the outer arc edge includes a first arcuate section having the same shape and arc length as that for the inner arc edge, and the wavelength conversion element is arranged so that concave sides of the inner arc edges and the outer arc edges face toward the inside of the base plate.