Color Wheel Segment Self-Alignment via Recess Peg Engagement
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Solution Overview
Problem
Existing color wheel technologies for projector systems face challenges in aligning and securing dichroic filter segments to a rotatable hub, requiring time-consuming and costly procedures that often compromise durability due to the need for additional balancing and mechanical securing methods.
Innovation Solution
A color wheel design featuring single-piece color filter segments with concave edge elements that engage with corresponding pegs on the hub, allowing for self-alignment and axial securing without additional platforms, using chemical bonds, mechanical snap mechanisms, or ultrasonic welding, which reduces assembly complexity and balancing effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive only is used to attach color filter segments to the hub, then assembly is simple, but alignment precision and securing reliability are insufficient under fast rotation
Solution Approach 1:
The color filter segment is designed with self-aligning features including a recess that automatically positions the segment onto the hub, and integrated balancing elements that self-adjust during assembly. The segment's geometry includes alignment ribs and corresponding grooves that guide precise positioning without requiring external alignment tools or procedures
Solution Approach 2:
The color filter segment combines multiple materials with complementary properties: a rigid glass or plastic filter layer for optical function, a flexible adhesive layer for secure bonding, and a metallic or dense plastic balancing layer integrated into the segment structure. This composite construction provides both precise alignment capability and secure attachment under centrifugal forces
2Ease of manufacture
If adhesive only is used to attach color filter segments to the hub, then assembly process is simple, but securing reliability under centrifugal forces is insufficient
Solution Approach 1:
The color filter segment combines multiple materials with complementary properties: a rigid glass or plastic filter layer for optical function, a flexible adhesive layer for secure bonding, and a metallic or dense plastic balancing layer integrated into the segment structure. This composite construction provides both precise alignment capability and secure attachment under centrifugal forces
Solution Approach 2:
The back surface of the color filter segment features a curved or domed geometry that distributes centrifugal forces evenly across the adhesive bonding area. This curvature design prevents stress concentration at flat surfaces and enhances the adhesive bond's resistance to detachment during high-speed rotation
3Reliability
If holes and screws are used to secure segments, then securing reliability improves, but assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The invention extracts and eliminates the complex hole-drilling and screw-securing operations from the assembly process. Instead, it employs an integrated adhesive bonding system with self-aligning geometric features that provide equivalent or superior securing reliability without requiring additional fastening components or complex assembly steps
Solution Approach 2:
The alignment features, securing mechanism, and balancing elements are merged into a single integrated color filter segment structure. The recess, alignment ribs, and balancing layer work together as one unified component that attaches to the hub in a single operation, eliminating the need for separate alignment and fastening procedures
4Manufacturing precision
If alignment procedures are added to secure segments, then alignment precision improves, but assembly time increases
Solution Approach 1:
The color filter segment is designed with self-aligning features including a recess that automatically positions the segment onto the hub, and integrated balancing elements that self-adjust during assembly. The segment's geometry includes alignment ribs and corresponding grooves that guide precise positioning without requiring external alignment tools or procedures
Solution Approach 2:
The alignment features such as recesses, ribs, and grooves are pre-formed during the color filter segment manufacturing process. This preliminary incorporation of alignment geometry eliminates the need for post-manufacturing alignment operations, as the segment is ready for precise self-alignment upon attachment to the hub
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
The solution enables a lightweight, cost-effective, and efficiently assembled color wheel with minimal balancing requirements, improving durability and simplifying the assembly process while maintaining stability under centrifugal forces.
Implementation Method 1
which are used to axially secure the segments to the hub... Securing is performed for example by chemical bond
Implementation Method 2
Securing is performed for example by chemical bond, mechanical snap mechanism ultrasonic welding
Data Source
AI summary
A color wheel for use in projector systems comprises a disc shaped hub, rotatable around a central axis and color filter segments arranged radially to said central axis and affixed to said hub. This color ring is arranged concentrically with respect to said axis and said segments' contour comprising an outer arc, an inner arc and two radial parts. Each of the radial parts comprises a recess arranged such that during assembly of said segments pairs of neighboring recesses form a hole which again engages in a corresponding peg on the hub in a form fitting manner.