Condenser Lens Thermal Interface for Laser Projectors
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Solution Overview
Problem
Current laser projectors face heat dissipation challenges in condenser lenses due to high rotation speeds leading to vibration, noise, and ineffective heat transfer, which can result in temperature rises and potential lens damage.
Innovation Solution
A wavelength conversion module is designed with a thermally conductive material between the condenser lens and lens holder, enhancing heat transfer and dissipation, and incorporating a support bracket and lens holder with a bearing surface to accommodate the condenser lens, allowing for improved thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the phosphor wheel rotates at high speed (7200 rpm to 14400 rpm) to generate wind flow for cooling, then heat dissipation from the condenser lens is improved, but vibration and system noise increase significantly
Solution Approach 1:
The patent extracts the heat dissipation function from the rotating phosphor wheel system by introducing a separate stationary fan assembly. This allows the phosphor wheel to operate at optimal speeds for light generation without being constrained by heat dissipation requirements, thereby reducing vibration and noise while maintaining effective cooling of the condenser lens through the dedicated fan-driven air flow.
2Volume of moving object
If the condenser lens volume is reduced to shrink the projection system size, then device compactness is improved, but heat dissipation capability per unit surface area deteriorates
Solution Approach 1:
The patent addresses the heat dissipation challenge of miniaturized condenser lenses by introducing a three-dimensional cooling solution: a fan assembly positioned to create directed air flow through dedicated air inlet and outlet openings in the lens holder. This dimensional approach to heat management allows effective cooling of small-volume lenses without increasing their physical size, maintaining compact system design while improving heat dissipation capability.
3Ease of manufacture
If the condenser lens has a ground surface instead of a polished surface due to manufacturing limitations, then manufacturing cost and complexity are reduced, but heat transfer efficiency to the lens holder deteriorates
Solution Approach 1:
The patent introduces thermal grease as an intermediary substance between the ground surface of the condenser lens and the bearing surface of the lens holder. This thermal interface material fills the microscopic gaps and irregularities inherent in ground surfaces, creating effective thermal contact pathways that enable efficient heat transfer from the lens to the holder without requiring costly polished surfaces, thus maintaining manufacturing simplicity while improving heat dissipation.
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
This design effectively reduces the temperature of the condenser lens, improves heat dissipation, and enhances the overall projection quality and competitiveness of the projection device.
Implementation Method 1
The thermally conductive material is disposed between the annular assembly surface of the condenser lens and the bearing surface of the lens holder to transfer heat from the condenser lens to the lens holder
Implementation Method 2
a commonly used method for dissipating heat from the condenser lens uses a wind flow generated by rotation of the phosphor wheel. When rotating at 7200 rpm to 14400 rpm, the phosphor wheel drives the surrounding air to flow, thereby cooling the condenser lens and a lens holder
Data Source
AI summary
A wavelength conversion module includes a wavelength conversion unit, a support bracket, a lens holder, a condenser lens, and a thermally conductive material. The wavelength conversion unit is disposed on the support bracket. The lens holder is disposed on the support bracket, and has an accommodation space to accommodate the condenser lens. An inner wall of the lens holder is arranged with a bearing surface. The condenser lens has an annular assembly surface. The condenser lens is disposed on the bearing surface through the annular assembly surface to be fixed to the lens holder. The thermally conductive material is disposed between the annular assembly surface of the condenser lens and the bearing surface of the lens holder to transfer heat from the condenser lens to the lens holder.