Manufacturing method for wavelength conversion device

• US 10,146,045 B2
• Filed: 10/08/2014
• Issued: 12/04/2018
• Est. Priority Date: 10/15/2013
• Status: Active Grant

• Current Assignee: Appotronics Corporation Limited
• Original Assignee: Appotronics Corporation Limited
• Inventors: Li, Qian, Xu, Yanzheng
• Primary Examiner(s): Vetere, Robert A
• Application Number:
  US15/028,926
• Publication Number:
  US 20160266375A1
• Time in Patent Office: 1,518 Days
• CPC Class Codes: C03C 17/001 General methods for coating; Devices therefor
• CPC Class Codes: G02B 26/008 in the form of devices for effecting sequential colour changes, e.g. colour wheels
• CPC Class Codes: G02B 5/0242 by means of dispersed particles
• CPC Class Codes: G02B 5/0268 characterized by the fabrication or manufacturing method
• CPC Class Codes: G02B 5/0284 used in reflection
• CPC Class Codes: G03B 21/204 using secondary light emission, e.g. luminescence or fluorescence using different colours G03B33/00; if related to video signals H04N9/3197
• CPC Class Codes: G03B 33/08 Sequential recording or projection G03B33/02, G03B33/04, G03B33/06 take precedence
• CPC Class Codes: H05B 33/10 Apparatus or processes specially adapted to the manufacture of electroluminescent light sources

Abstract

Disclosed is a manufacturing method for a wavelength conversion device, comprising: preparing a plurality of wavelength conversion modules, each wavelength conversion module comprising a ceramic substrate, a reflecting layer and a fluorescent powder layer, said layers being stacked sequentially and formed into one piece; installing and fixing the plurality of wavelength conversion modules on one surface of a base substrate. By arranging different fluorescent powders respectively on the different wavelength conversion modules, a plurality of wavelength conversion modules can be produced separately at the same time, thereby significantly shortening the production cycle. Each such module is produced independently and is thus not subject to the restrictions of the characteristics of other fluorescent powders. This is beneficial for the optimization of the various processes, and a wavelength conversion device having optimal performance is thereby obtained.

Claims

1. A method for fabricating a wavelength conversion device, comprising:

separately preparing a plurality of wavelength conversion modules, each wavelength conversion module including a ceramic substrate, a reflective layer and a wavelength conversion layer, which are sequentially stacked together forming an integral unit, wherein the wavelength conversion layers of at least some of the plurality of wavelength conversion modules include wavelength conversion materials that are different from each other; and

affixing the plurality of wavelength conversion modules that have been separately prepared on a surface of a common base plate.

2. The method of claim 1, wherein the reflective layer is a diffuse reflection layer, formed by sintering a diffusing material slurry which includes white scattering particles, a first glass powder and an organic carrier.

3. The method of claim 2, wherein the wavelength conversion layer is formed by sintering a phosphor slurry which includes a phosphor powder, a second glass powder and an organic carrier.

4. The method of claim 3, wherein the step of forming each wavelength conversion module includes:

coating the diffusing material slurry on the ceramic substrate, and sinter it to form the diffuse reflection layer; and

coating the phosphor material slurry on the diffuse reflection layer, and sintering it to form the wavelength conversion layer, to obtain the wavelength conversion module, wherein a softening point of the first glass powder in the diffusing material slurry is higher than a softening point of the second glass powder in the phosphor material slurry.

5. The method of claim 3, wherein the step of forming each wavelength conversion module includes:

coating the phosphor material slurry on a substrate, and sintering it to form the wavelength conversion layer;

coating the diffusing material slurry on the wavelength conversion layer, and sinter it to form the diffuse reflection layer, wherein a softening point of the second glass powder in the phosphor material slurry is higher than a softening point of the first glass powder in the diffusing material slurry;

releasing the substrate to obtain the diffuse reflection layer having the phosphor layer adhered to one side of it, and adhering or sintering another side of the diffuse reflection layer to the ceramic substrate, to obtain the wavelength conversion module.

6. The method of claim 3, wherein each of the first glass powder and the second glass powder is selected from a group consisting of silicate glass, lead silicate glass, aluminum borosilicate glass, aluminate glass, soda lime glass, and quartz glass, or is a mixture of two or more of the above substances.

7. The method of claim 2, wherein the white scattering particles are selected from aluminum oxide, titanium oxide, aluminum nitride, magnesium oxide, boron nitride, zinc oxide, zirconium oxide and barium sulfate, or are a mixture of two or more of the above substance.

8. The method of claim 1, wherein the wavelength conversion layer is formed by curing a mixture of silica gel and a phosphor powder.

9. The method of claim 1, wherein each wavelength conversion module includes only one color phosphor, and wherein different color phosphors are located on different wavelength conversion modules.

10. The method of claim 1, further comprising:

preparing one or more fluorescent ceramic modules, each fluorescent ceramic module including a fluorescent ceramic block and a total reflection film disposed on a bottom surface of the fluorescent ceramic block; and

affixing the fluorescent ceramic modules along with the wavelength conversion modules on the surface of the base plate.

11. The method of claim 10, wherein a step of fabricating each fluorescent ceramic module includes:

obtaining the fluorescent ceramic block; and

coating the total reflection film on the bottom surface of the fluorescent ceramic block.

12. The method of claim 11, wherein the step of fabricating each fluorescent ceramic module further includes:

coating a metal protection film over the total reflection film.

13. The method of claim 10, wherein each of the wavelength conversion modules or fluorescent ceramic modules is affixed on their bottom to the base plate using adhesion, soldering, or mechanical fastening means.

14. The method of claim 1, wherein each of the wavelength conversion modules or fluorescent ceramic modules is affixed on their bottom to the base plate using adhesion, soldering, or mechanical fastening means.

15. The method of claim 1, wherein the base plate is formed of a metal, a metal alloy, or a composite material of metal and inorganic materials.