Color wheel and light source system

Abstract

The embodiment of the present application provides a color wheel, comprising: a substrate, the substrate having a first surface and a second surface opposite to each other; a wavelength conversion layer, the wavelength conversion layer being arranged on the first surface; a plurality of impeller fins, the plurality of impeller fins being arranged on the second surface at intervals around a central axis of the substrate; a cover plate, the cover plate being arranged at one end of the plurality of impeller fins away from the second surface and opposite to the second surface; and a heat dissipation piece, the heat dissipation piece being arranged on the second surface and located outside the plurality of impeller fins. The structure of the inner ring impeller fin and the cover plate forms forced convection cooling air, the cooling air directly flows to the heat dissipation piece of the outer ring which is radially thrown out by the impeller fin, forms large-area and high-efficiency convection heat exchange, and significantly improves the heat dissipation effect of the color wheel. In addition, the embodiment of the present application also provides a light source system.

Description

Technical Field

[0001] This application relates to the field of color wheel technology, specifically to a color wheel and a light source system. Background Technology

[0002] In laser-based projectors with a color wheel, the color wheel's role is to excite the phosphor material on its substrate to generate light of other wavelengths after receiving incident light. This wavelength conversion process is not 100% efficient; therefore, the energy lost during wavelength conversion manifests as heat. Although the rotation of the color wheel distributes the heat generation area from a very small spot to a larger ring-shaped region, the increasing demand for high performance and high brightness in the projection industry makes heat dissipation of the color wheel even more challenging. Current color wheel heat dissipation solutions are insufficient, making improvements to color wheel heat dissipation crucial.

[0003] In existing technologies, such as Figure 1 As shown, some color wheel structures dissipate heat by providing heat sinks 23 on the substrate 22. When this type of color wheel is in operation, the substrate 22 rotates, causing airflow. During this airflow, heat exchange occurs between the airflow and the heat sinks 23 and the substrate 22, thus carrying away heat. The drawback of this heat dissipation method is that when the color wheel operates for a long time, the heat dissipation area is small, resulting in insufficient heat dissipation and potential heat buildup.

[0004] like Figure 2 This illustrates another color wheel structure in the prior art, which, compared to... Figure 1 The color wheel in the heat sink 23 has a cover plate 24. By setting the cover plate, the airflow path can be guided, improving the heat dissipation efficiency compared to... Figure 1 The color wheel shown has better heat dissipation, but it still cannot meet the heat dissipation requirements of high-performance color wheels. Utility Model Content

[0005] This application provides a color wheel and light source system to at least partially improve the above-mentioned technical problems.

[0006] In a first aspect, embodiments of this application provide a color wheel, comprising: a substrate having a first surface and a second surface facing away from each other; a wavelength conversion layer disposed on the first surface; a plurality of impeller heat sinks spaced apart around the central axis of the substrate on the second surface; a cover plate disposed at one end of the plurality of impeller heat sinks away from the second surface and opposite to the second surface; and a heat dissipation member disposed on the second surface and located outside the plurality of impeller heat sinks.

[0007] In one embodiment, the heat sink includes a plurality of spaced-apart heat sink fins, which are arranged in a ring and surround the plurality of impeller heat sink fins.

[0008] In one embodiment, the spacing between adjacent heat dissipation fins is smaller than the spacing between adjacent impeller heat dissipation fins.

[0009] In one embodiment, the spacing between adjacent heat dissipation fins is 1mm-2mm.

[0010] In one embodiment, the heat sink is disposed corresponding to the wavelength conversion layer.

[0011] In one embodiment, the heat sink includes a snap-on heat sink, a 3D-printed heat sink, or a porous heat sink.

[0012] In one embodiment, the heat dissipation fins are fixedly connected to the substrate by reflow soldering.

[0013] In one embodiment, the plurality of impeller heat sinks are integrally formed with the substrate.

[0014] In one embodiment, the cover plate at least partially covers the plurality of impeller heat sinks along the radial direction of the substrate.

[0015] In one embodiment, the color wheel further includes a driver connected to the substrate and used to drive the substrate to rotate.

[0016] Secondly, embodiments of this application provide a light source system, including a color wheel and an excitation light source as described in the first aspect above.

[0017] Compared with the prior art, the present invention has the following beneficial effects: The color wheel and light source system provided in the embodiments of this application, when the color wheel starts to work, the substrate is driven to rotate, the wavelength conversion layer receives the excitation light and performs wavelength conversion, and heat is generated during the conversion process. The heat is transferred from the first surface to the heat dissipation component and impeller heat dissipation fins on the second surface. The structure of the inner ring impeller heat dissipation fins and the cover plate forms forced convection cooling air. The cooling air thrown radially out by the impeller heat dissipation fins flows directly to the heat dissipation component of the outer ring, forming a large-area and efficient convection heat exchange, which significantly improves the heat dissipation effect of the color wheel. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of a color wheel in the prior art; Figure 2 This is a schematic diagram of the structure of a color wheel in another existing technology; Figure 3 This is a schematic diagram of the structure of a light source system proposed in an embodiment of this application; Figure 4 This is a schematic diagram of a color wheel according to an embodiment of this application; Figure 5 for Figure 4 A schematic diagram of the split structure of the color wheel is shown; Figure 6 for Figure 4 A schematic diagram of a half-section of the color wheel is shown; Figure 7 This is a schematic diagram of the heat flow direction of a color wheel according to an embodiment of this application; Figure 8 This is a schematic diagram illustrating the heat dissipation working principle of a color wheel according to an embodiment of this application; Figure 9 for Figure 1 The heat dissipation simulation cloud diagram of the color wheel is shown in the image; Figure 10 for Figure 2 The heat dissipation simulation cloud diagram of the color wheel is shown in the image; Figure 11 for Figure 4 The image shows a heat dissipation simulation cloud diagram of the color wheel. Detailed Implementation

[0020] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without inventive effort are within the scope of protection of the present application.

[0021] In this application, unless otherwise expressly specified or limited, the terms "installation," "connection," "fixation," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components; they can refer to mere surface contact; or they can refer to surface contact connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0022] Furthermore, the terms "first," "second," etc., are used only for distinguishing descriptions and should not be construed as referring to specific or particular structures. The terms "some embodiments," "other embodiments," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this application, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. Furthermore, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this application, as well as the features of different embodiments or examples.

[0023] Example This application provides a light source system 1, please refer to... Figure 3 The light source system 1 includes a color wheel 10 and an excitation light source 20.

[0024] Please refer to the following: Figure 4 and Figure 5 In this embodiment, the color wheel 10 includes a substrate 11, a wavelength conversion layer 12, an impeller heat sink 13, a cover plate 15, and a heat sink 18. The wavelength conversion layer 12 and the impeller heat sink 13 can be disposed on the substrate 11, the cover plate 15 is connected to the impeller heat sink 13, and the heat sink 18 is disposed on the substrate and located outside the impeller heat sink 13.

[0025] Specifically, please combine them together Figure 4 and Figure 6 The substrate 11 can be made of metal, which has a certain strength and can also be used to achieve rapid heat conduction.

[0026] Please continue reading. Figure 6 The substrate 11 has a first surface 111 and a second surface 112 facing away from each other. A wavelength conversion layer 12 is disposed on the first surface 111. The wavelength conversion layer 12 can receive excitation light and convert it into a laser beam of a preset wavelength. The wavelength conversion layer 12 can be a phosphor layer or the like. In this embodiment, the substrate 11 has a generally circular structure. In other embodiments, the substrate 11 can also be other shapes.

[0027] In this embodiment, please continue to refer to Figure 3 as well as Figure 6 The excitation light emitted from the excitation source 20 has a certain amount of energy. Under long-term irradiation, the temperature of the wavelength conversion layer 12 rises sharply. The high-temperature environment will seriously affect the conversion efficiency of the wavelength conversion layer 12.

[0028] In this embodiment, a plurality of impeller heat sinks 13 are disposed on the second surface 112. The plurality of impeller heat sinks 13 are spaced apart around the central axis of the substrate 11 on the second surface 112. A first air duct 131 can be formed between adjacent impeller heat sinks 13. The first air duct 131 is used to allow airflow to pass through, so that heat exchange can occur between the airflow and the impeller heat sinks 13. It is understood that the plurality of first air ducts 131 are spaced apart from each other.

[0029] The impeller heat sink 13 can be made of the same material as the substrate 11, such as metal, to improve heat transfer efficiency and reduce thermal resistance. In some embodiments, the impeller heat sink 13 can be integrally formed with the substrate 11. This integral forming method can reduce thermal resistance and improve heat transfer efficiency. Of course, in other embodiments, the impeller heat sink 13 can also be connected to the substrate 11 by welding or other means. This embodiment does not limit this.

[0030] Please continue reading. Figure 6 The cover plate 15 is disposed at the end of the plurality of impeller heat sinks 13 away from the second surface 112 and is opposite to the second surface 112.

[0031] In some embodiments, the cover plate 15 may also cover at least part of the plurality of impeller heat sinks 13 along the radial direction of the substrate 11, that is, the cover plate 15 covers at least a part of the first air duct 131, that is, the cover plate 15 forms a shield for the first air duct 131. When the airflow flows through the first air duct 131, the airflow is blocked by the cover plate 15, thereby guiding the flow of the airflow so that the airflow flows towards the outer heat sink 18. During the guiding process, the airflow can also directly contact the cover plate 15 for heat exchange.

[0032] The cover plate 15 can also be made of the same material as the impeller heat sink 13, such as metal, to improve heat transfer efficiency and reduce thermal resistance. In some embodiments, the impeller heat sink 13 can be integrally formed with the cover plate 15, or connected by welding or other methods. By providing the cover plate 15, the cover plate 15 can precisely guide the airflow through the first air duct 131, improving heat exchange efficiency. At the same time, since the cover plate 15 is directly connected to the impeller heat sink 13 for heat transfer, it can also directly form heat exchange with the airflow through the first air duct 131, further improving heat exchange efficiency and thus improving heat dissipation.

[0033] Preferably, the cover plate 15 can be configured such that its orthographic projection on the second surface 112 at least covers the orthographic projection of the plurality of impeller heat sinks 13 on the second surface 112, that is, the cover plate 15 completely covers the plurality of impeller heat sinks 13. This implementation can further improve the guiding function of the first air duct 131, while increasing the area of ​​the cover plate 15, thereby increasing the heat exchange efficiency between the cover plate 15 and the airflow.

[0034] In this embodiment, please continue to refer to Figure 4 and Figure 6 The heat sink 18 is disposed on the second surface 112 and located outside the plurality of impeller heat sinks 13. The heat sink 18 may be made of the same material as the substrate 11, for example, both may be made of metal, in order to improve heat transfer efficiency and reduce thermal resistance. In some embodiments, the heat sink 18 may be integrally formed with the substrate 11 or connected by means of welding or other methods. The materials of the heat sink and the substrate may also be different.

[0035] See Figure 7 In this embodiment, by providing a heat sink 18, when the substrate 11 rotates, airflow is drawn in along the axial direction. The structure of the inner impeller heat sink 13 and the cover plate 15 forms forced convection cooling air. The cooling air radially ejected by the impeller heat sink 13 flows directly to the outer heat sink 18. During this process, the airflow exchanges heat with the impeller heat sink 13 and the cover plate 15, and then further exchanges heat with the heat sink 18, forming a large-area, highly efficient convection heat exchange, significantly improving the heat dissipation effect of the color wheel 10. Compared with the prior art, the heat dissipation area is increased by 70%.

[0036] In this embodiment, the heat sink may include a snap-fit ​​fin radiator. The snap-fit ​​fin radiator can be manufactured using a process where aluminum sheets are stamped and then snapped together, allowing for thinner fins and smaller fin gaps compared to other heat sink manufacturing processes, thereby increasing the overall heat dissipation area. Specifically, in this embodiment, the heat sink 18 includes multiple spaced-apart heat sink fins 181, arranged in a ring and surrounding the multiple impeller heat sinks 13. The heat sink fins 181 can be integrally connected to the substrate 11. In this embodiment, the heat sink fins 181 are fixedly connected to the substrate 11 by reflow soldering. Reflow soldering offers advantages such as high production efficiency, high welding quality, wide applicability, environmental compliance, simplified process, and high control precision. This results in a stable structure and precise positioning of the multiple heat sink fins 181 formed in this way.

[0037] A second air duct 183 can be formed between adjacent heat dissipation fins 181, and the first air duct 131 is connected to the second air duct 183. When airflow exits from the first air duct 131, it can enter the second air duct 183 and exchange heat with the heat dissipation fins 181 within the second air duct 183. By forming the second air duct 183, the flow direction of airflow can be further guided, thereby improving the heat exchange effect.

[0038] In some embodiments, the first air duct 131 may have the same extending direction as the second air duct 183, so that the airflow from the first air duct 131 into the second air duct 183 can flow more smoothly, reducing resistance and noise generation. In this embodiment, the first air duct 131 and the second air duct 183 have different extending directions, that is, the airflow direction changes when the airflow flows from the first air duct 131 into the second air duct 183. This can prolong the airflow time and improve the heat exchange effect between the airflow and the heat dissipation fins 181.

[0039] Specifically, in this embodiment, the second air duct 183 extends radially along the substrate 11, that is, the heat dissipation fins 181 extend radially along the substrate 11. In this embodiment, the spacing between adjacent heat dissipation fins 181 is smaller than the spacing between adjacent impeller heat dissipation fins 13, that is, the width of the second air duct 183 is smaller than the width of the first air duct 131. The advantage of this arrangement is that it can increase the number of heat dissipation fins 181, thereby increasing the heat exchange area, increasing the heat dissipation area, and improving the heat dissipation effect. Preferably, the spacing between adjacent heat dissipation fins 181 can be 1mm-2mm, and particularly, the spacing between adjacent heat dissipation fins 181 can be 1.5mm.

[0040] In some other embodiments, the heat sink 18 may also include a 3D printed heat sink or a porous heat sink, which is not limited in this embodiment.

[0041] In this embodiment, the wavelength conversion layer 12 is disposed on the first surface 111 and is offset from the impeller heat sink 13. Specifically, the wavelength conversion layer 12 is located on the outside of the impeller heat sink 13.

[0042] Preferably, in this embodiment, the heat sink 18 can be disposed corresponding to the wavelength conversion layer 12. The advantage of this arrangement is that when the excitation light is incident on the wavelength conversion layer 12, heat accumulates in the wavelength conversion layer 12, and the heat of the wavelength conversion layer 12 is transferred to the substrate 11. At this time, most of the heat is transferred to the heat sink 18. Since the heat sink has a large heat dissipation area, the heat exchange contact area with the airflow is increased, and the heat dissipation efficiency is improved. A small part of the heat can be transferred to the impeller heat sink 13.

[0043] In some embodiments, the color wheel 10 may further include a driver 19, and a through hole 113 is provided in the middle of the substrate 11 for connecting the substrate 11 to the driver 19. The driver 19 may be, for example, a motor, and is used to drive the substrate to rotate. This embodiment does not limit this aspect.

[0044] See Figure 8 The heat dissipation working principle of the color wheel 10 provided in this embodiment is as follows: the excitation light source 20 emits excitation light toward the wavelength conversion layer 12, and the wavelength conversion layer 12 converts at least part of the excitation light into laser light. During this process, heat begins to accumulate in the wavelength conversion layer 12, and the heat is transferred to the heat sink and impeller heat sink on the substrate 11. Most of the energy is transferred to the heat sink 18, and a small part of the heat is transferred to the impeller heat sink 13. During this process, the substrate 11 rotates, and the airflow enters from the axial direction and flows out from the first air channel 131 along the radial direction of the substrate 11. It exchanges heat with the impeller heat sink 13, the cover plate 15 and the substrate 11. After heat exchange, the airflow forms forced convection cooling air through the structure of the inner impeller heat sink 13 and the cover plate 15. The cooling air thrown out radially by the impeller heat sink 13 flows directly to the outer heat sink 18 and continues to exchange heat with the heat sink fins 181, thereby taking away the heat on the heat sink 18 and forming a large-area, efficient convection heat exchange, which significantly improves the heat dissipation effect of the color wheel.

[0045] To verify the heat dissipation effect of the color wheel provided in the embodiments of this application, the following was conducted: Figure 1 , Figure 2 as well as Figure 4 Simulation tests were conducted on the color wheel shown, with test conditions such as the output power of the excitation light source and the rotation speed of the substrate 11 remaining consistent.

[0046] Figure 9 It shows Figure 1 The simulated cloud map of the color wheel in the image, where Figure 9 Different colored areas represent different temperatures, with the temperature unit being °C. Figure 9 As can be seen, the temperature of the wavelength conversion layer region in the color wheel is 93.5℃, and the temperature at the center of the color wheel rotation (i.e., the motor shaft) is 81℃.

[0047] Figure 10 It shows Figure 2 The simulated cloud map of the color wheel in the image, where Figure 10 Different colored areas represent different temperatures, with the temperature unit being °C. Figure 10 It can be seen that the temperature in the wavelength conversion layer region of the color wheel is 91.6℃, and the temperature at the center of the color wheel's rotation (i.e., the motor shaft) is 79.4℃. Compared to... Figure 1In the color wheel, under the same conditions, the temperature at the center of rotation of the color wheel (i.e., at the motor shaft or motor shaft) drops by 1.6℃, and the temperature in the wavelength conversion layer region drops by 1.9℃.

[0048] Figure 11 It shows Figure 4 The simulated cloud map of the color wheel in the image, where Figure 11 Different colored areas represent different temperatures, with the temperature unit being °C. Figure 11 It can be seen that the temperature in the wavelength conversion layer region of the color wheel is 87℃, and the temperature at the center of the color wheel's rotation (i.e., the motor shaft) is 75.8℃. Compared to... Figure 1 In the color wheel, under the same conditions, the temperature at the center of rotation of the color wheel (i.e., at the motor shaft) drops by 5.2℃, and the temperature in the wavelength conversion layer region drops by 6.5℃. It is evident that by providing a heat sink on the outside of the impeller heat sink 13, the heat dissipation effect of the color wheel 10 is significantly further improved.

[0049] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A color wheel, characterized in that, include: A substrate having a first surface and a second surface facing away from each other; A wavelength conversion layer is disposed on the first surface; Multiple impeller heat sinks are spaced apart on the second surface around the central axis of the substrate; A cover plate is disposed at one end of the plurality of impeller heat sinks that is away from the second surface and is opposite to the second surface; as well as A heat sink is disposed on the second surface and located outside the plurality of impeller heat sinks.

2. The color wheel according to claim 1, characterized in that, The heat sink includes a plurality of spaced-apart heat sink fins, which are arranged in a ring and surround the plurality of impeller heat sink fins.

3. The color wheel according to claim 2, characterized in that, The spacing between adjacent heat dissipation fins is smaller than the spacing between adjacent impeller heat dissipation fins.

4. The color wheel according to claim 3, characterized in that, The spacing between adjacent heat dissipation fins is 1mm-2mm.

5. The color wheel according to claim 1, characterized in that, The heat sink is disposed correspondingly to the wavelength conversion layer.

6. The color wheel according to claim 1, characterized in that, The heat sink includes a snap-on heat sink, a 3D-printed heat sink, or a porous heat sink.

7. The color wheel according to claim 2, characterized in that, The heat dissipation fins are fixedly connected to the substrate by reflow soldering.

8. The color wheel according to claim 1, characterized in that, The plurality of impeller heat sinks are integrally formed with the substrate.

9. The color wheel according to claim 1, characterized in that, The cover plate at least partially covers the plurality of impeller heat sinks along the radial direction of the substrate.

10. The color wheel according to claim 1, characterized in that, The color wheel also includes a driver connected to the substrate and used to drive the substrate to rotate.

11. A light source system, characterized in that, include: The color wheel as described in any one of claims 1-10; and Excite the light source.

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