Effects of Coating Film Parameters on Thermal and Stress Distributions of Glass-Based Phosphor-Converted Color Wheels

To protect the environment, the use of mercury tubes has been prohibited in Europe since 2000. As an alternative, phosphor-doped silicone resin wheels have been used to convert blue-ray laser diodes. However, high-temperature photonic decay and cracking on the lens surface significantly degrade transmission. Recent research has explored the possibility of replacing the silicone encapsulant material of the phosphor layer with glass. In this study, the thermal effects of a glass-based phosphor-converted color wheel (GP wheel) and a silicone-based phosphor-converted color wheel (SP wheel) were investigated using various parameters and geometries. A thermal-structural coupling finite element (FE) model of the color wheels was employed to simulate the thermal and stress distributions. To construct the FE model, experiments were conducted and the inverse engineering approach was employed to extract the optical-to-heat conversion coefficient and the heat convection coefficient. In addition, an arc-shaped moving input heat flux was used to simulate a moving laser input and reduce the calculation time of the FE model. Based on the numerical and experimental results, the FE model developed can simulate the steady/transient behavior of the resin and the GP wheel. In addition, the results reveal that thermal failures of the SP wheel are very likely to occur under all parameters employed in this study, whereas the maximum temperature of the GP wheel reaches only approximately 40% of the glass transition temperature. The numerical results indicate that the GP wheel may be useful for overcoming all of these thermal disadvantages in a high-power laser-lit projector.