Wavelength conversion module, forming method of wavelength conversion module, and projection device

• US 10,663,847 B2
• Filed: 02/27/2019
• Issued: 05/26/2020
• Est. Priority Date: 04/28/2018
• Status: Active Grant

• Current Assignee: Coretronic Corporation
• Original Assignee: Coretronic Corporation
• Inventors: Chen, I-Hua, Hsieh, Chi-Tang, Hsu, Jo-Han, Tsai, Chia-Lun
• Primary Examiner(s): Chowdhury, Sultan
• Application Number:
  US16/286,613
• Publication Number:
  US 20190331989A1
• Time in Patent Office: 454 Days
• CPC Class Codes: G03B 21/16 Cooling; Preventing overheating
• 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 21/2066 Reflectors in illumination beam in projection beam G03B21/28
• CPC Class Codes: G03B 33/08 Sequential recording or projection G03B33/02, G03B33/04, G03B33/06 take precedence

Abstract

A wavelength conversion module, a forming method of a wavelength conversion module, and a projection device are provided. The wavelength conversion module includes a substrate and a plurality of wavelength conversion units. The wavelength conversion units are located on the substrate, wherein the wavelength conversion units include a first wavelength conversion unit and a second wavelength conversion unit, the first wavelength conversion unit includes a first wavelength conversion material and a first doping material, the second wavelength conversion unit includes a second wavelength conversion material and a second doping material, the first wavelength conversion material and the second wavelength conversion material are different from each other, and the first doping material and the second doping material are different from each other. By the wavelength conversion units comprising different doping materials, low cost, good heat resistance and efficient light emitting are achieved.

Claims

1. A wavelength conversion module, having a plurality of optical regions, and comprising:

a substrate; and

a plurality of wavelength conversion units located on the substrate, wherein the plurality of wavelength conversion units are correspondingly disposed on the plurality of optical regions respectively, wherein the plurality of wavelength conversion units comprise a first wavelength conversion unit and a second wavelength conversion unit, the first wavelength conversion unit comprises a first wavelength conversion material and a first doping material, and the second wavelength conversion unit comprises a second wavelength conversion material and a second doping material, and wherein the first wavelength conversion material and the second wavelength conversion material are different from each other, and the first doping material and the second doping material are different from each other, wherein the first wavelength conversion unit has a first illuminating surface, the second wavelength conversion unit has a second illuminating surface, and a minimum distance from the first illuminating surface to the substrate and a minimum distance from the second illuminating surface to the substrate are different from each other.

2. The wavelength conversion module according to claim 1, wherein when the first wavelength conversion material contains phosphor powders for yellow, the first doping material contains ceramic or silicon dioxide.

3. The wavelength conversion module according to claim 1, wherein when the second wavelength conversion material contains phosphor powders for green, the second doping material contains one of silicone, ceramic and silicon dioxide.

4. The wavelength conversion module according to claim 1, wherein the minimum distance from the first illuminating surface to the substrate and the minimum distance from the second illuminating surface to the substrate have therebetween a difference not exceeding 2 mm.

5. A wavelength conversion module, having a plurality of optical regions, and comprising:

a substrate, wherein the substrate has a first surface and a second surface opposite each other; and

a plurality of wavelength conversion units located on the substrate, wherein the plurality of wavelength conversion units are correspondingly disposed on the plurality of optical regions respectively, wherein the plurality of wavelength conversion units comprise a first wavelength conversion unit and a second wavelength conversion unit, the first wavelength conversion unit comprises a first wavelength conversion material and a first doping material, and the second wavelength conversion unit comprises a second wavelength conversion material and a second doping material, and wherein the first wavelength conversion material and the second wavelength conversion material are different from each other, the first doping material and the second doping material are different from each other, wherein

the first wavelength conversion unit further comprises;

a first wavelength conversion layer, wherein the first wavelength conversion material and the first doping material are located within the first wavelength conversion layer;

a first reflective layer located between the first wavelength conversion layer and the first surface of the substrate; and

a first heat dissipating base layer, wherein the substrate is located between the first heat dissipating base layer and the first reflective layer;

and wherein the second wavelength conversion unit further comprises;

a second wavelength conversion layer, wherein the second wavelength conversion material and the second doping material are located within the second wavelength conversion layer;

a second reflective layer located between the second wavelength conversion layer and the first surface of the substrate; and

a second heat dissipating base layer located between the second reflective layer and the first surface of the substrate.

6. The wavelength conversion module according to claim 5, wherein the first heat dissipating base layer is located on the second surface, and the second heat dissipating base layer is located on the first surface.

7. The wavelength conversion module according to claim 5, wherein the first reflective layer has a first reflective plane, the second reflective layer has a second reflective plane, and wherein the first reflective plane, the second reflective plane and the first surface of the substrate are not coplanar with one another.

8. A forming method of a wavelength conversion module, comprising:

providing a substrate, wherein the substrate has a plurality of regions, and the plurality of regions comprise a first region and a second region;

forming a mixture by mixing a first wavelength conversion material in a first doping material and sintering the mixture to provide a first wavelength conversion layer to the first region of the substrate, wherein the first wavelength conversion material and the first doping material are located within the first wavelength conversion layer;

attaching the first wavelength conversion layer to the first region of the substrate; and

forming a second wavelength conversion layer in the second region of the substrate, wherein a second wavelength conversion material and a second doping material are located within the second wavelength conversion layer, the first wavelength conversion material and the second wavelength conversion material are different from each other, and the first doping material and the second doping material are different from each other.

9. The forming method of a wavelength conversion module according to claim 8, wherein the second wavelength conversion layer is formed after the step of attaching the first wavelength conversion layer.

10. The forming method of a wavelength conversion module according to claim 8, wherein the first wavelength conversion layer is provided and attached after the step of forming the second wavelength conversion layer.

11. The forming method of a wavelength conversion module according to claim 8, wherein the step of forming the second wavelength conversion layer comprises:

coating a solution obtained by mixing the second wavelength conversion material in the second doping material on the second region of the substrate; and

curing the second wavelength conversion layer.

12. A projection device, comprising:

a wavelength conversion module having a plurality of optical regions, and comprising;

a substrate; and

a plurality of wavelength conversion units located on the substrate and correspondingly disposed on the plurality of optical regions respectively, wherein the plurality of wavelength conversion units comprise a first wavelength conversion unit and a second wavelength conversion unit, the first wavelength conversion unit comprises a first wavelength conversion material and a first doping material, the second wavelength conversion unit comprises a second wavelength conversion material and a second doping material, the first wavelength conversion material and the second wavelength conversion material are different from each other, and the first doping material and the second doping material are different from each other, wherein the first wavelength conversion unit has a first illuminating surface, the second wavelength conversion unit has a second illuminating surface, and a minimum distance from the first illuminating surface to the substrate and a minimum distance from the second illuminating surface to the substrate are different from each other;

an excitation light source configured to emit an excitation beam, wherein the excitation beam is transmitted to the wavelength conversion module and is converted into an illumination beam by the wavelength conversion module;

a light valve located on a transmission path of the illumination beam and configured to convert the illumination beam into an image beam; and

a projection lens located on a transmission path of the image beam and configured to convert the image beam into a projection beam.

13. The projection device according to claim 12, further comprising:

a condenser lens located between the excitation light source and the wavelength conversion module.

14. The projection device according to claim 13, wherein when the first wavelength conversion unit enters an irradiation range of the excitation beam, a first perpendicular distance exists between the first illuminating surface and the condenser lens, and when the second wavelength conversion unit enters the irradiation range of the excitation beam, a second perpendicular distance exists between the second illuminating surface and the condenser lens, and wherein a value of the first perpendicular distance is different from a value of the second perpendicular distance.

15. The projection device according to claim 14, wherein a difference between the value of the first perpendicular distance and the value of the second perpendicular distance does not exceed 2 mm.

16. The projection device according to claim 14, wherein when the first wavelength conversion material contains phosphor powders for yellow, the first doping material contains ceramic or silicon dioxide.

17. The projection device according to claim 16, wherein when the first wavelength conversion material contains the phosphor powders for yellow, the first perpendicular distance is greater than the second perpendicular distance.

18. The projection device according to claim 14, wherein when the second wavelength conversion material contains phosphor powders for green, the second doping material contains one of silicone, ceramic and silicon dioxide.

19. The projection device according to claim 12, wherein the substrate has a first surface and a second surface opposite each other, and wherein

the first wavelength conversion unit further comprises:

a first wavelength conversion layer, wherein the first wavelength conversion material and the first doping material are located within the first wavelength conversion layer;

a first reflective layer located between the first wavelength conversion layer and the first surface of the substrate; and

a first heat dissipating base layer, wherein the substrate is located between the first heat dissipating base layer and the first reflective layer;

and the second wavelength conversion unit further comprises;

a second wavelength conversion layer, wherein the second wavelength conversion material and the second doping material are located within the second wavelength conversion layer;

a second reflective layer located between the second wavelength conversion layer and the first surface of the substrate; and

a second heat dissipating base layer located between the second reflective layer and the first surface of the substrate.

20. The projection device according to claim 19, wherein the first heat dissipating base layer is located on the second surface, and the second heat dissipating base layer is located on the first surface.

21. The projection device according to claim 19, wherein the first reflective layer has a first reflective plane, the second reflective layer has a second reflective plane, and wherein the first reflective plane, the second reflective plane and the first surface of the substrate are not coplanar with one another.