Converter Arrangement Cooling via Axial Pivot and Composite Carrier
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Solution Overview
Problem
Converter arrangements for high-luminance light sources face challenges in efficient cooling, leading to accelerated material degradation, decreased conversion efficiency, and color changes in emitted light due to excessive temperatures, particularly in fast-rotating systems where heat dissipation is limited by the carrier's thermal connection rather than the converter itself.
Innovation Solution
A converter arrangement featuring an axially pivotable carrying wheel with a large surface area-to-boundary curve ratio, utilizing high thermal conductivity materials like metals or heat-conductive plastics, and opto-ceramics with a closed ring design or segmented configuration for improved heat distribution and thermal stability, along with a metallic solder connection for enhanced thermal conductivity and reflectivity, and increased emissivity of uncovered areas for effective heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the converter arrangement uses a compact design with small total area, then the device complexity is reduced, but the heat dissipation capability deteriorates leading to excessive temperatures
Solution Approach 1:
The invention transitions from a two-dimensional planar converter design to a three-dimensional spherical or curved surface converter arrangement. This dimensional change allows the converter to distribute heat over a larger surface area while maintaining a compact overall form factor, effectively resolving the contradiction between compact design and heat dissipation capability.
Solution Approach 2:
The invention employs composite structures combining the converter layer with a thermally conductive carrier material. This composite design enables efficient heat transfer from the converter to the carrier, which then dissipates heat to the environment, allowing compact design while maintaining effective cooling.
2Temperature
If the converter arrangement uses a large total area to improve heat dissipation, then the temperature is reduced, but the device complexity increases
Solution Approach 1:
By utilizing three-dimensional spherical or curved surfaces, the invention achieves large heat dissipation area without proportionally increasing the device's overall size or complexity. The curved geometry naturally provides surface area expansion while maintaining structural integrity and compact form.
Solution Approach 2:
The carrier structure serves multiple functions: it provides mechanical support for the converter, acts as a heat sink for thermal management, and can be designed with integrated cooling features. This multi-functionality reduces the need for separate cooling components, thereby limiting the increase in device complexity.
3Productivity
If the converter uses fast rotation to increase luminance output, then the productivity is improved, but the heat dissipation capability deteriorates due to limited thermal connection
Solution Approach 1:
The invention uses composite structures with thermally conductive materials connecting the converter to the carrier. This ensures efficient heat transfer even during fast rotation, preventing heat buildup that would otherwise limit the achievable luminance output and maintaining energy dissipation efficiency.
Solution Approach 2:
The three-dimensional curved surface geometry provides enhanced thermal pathways and larger effective heat dissipation area, improving heat transfer efficiency during high-speed rotation and enabling sustained high luminance output without excessive heat accumulation.
4Illumination intensity
If the converter operates at high temperatures to maintain luminance, then the brightness is maintained, but the reliability deteriorates due to accelerated material degradation
Solution Approach 1:
The thermally conductive carrier material in the composite structure actively manages heat away from the converter, preventing excessive temperature accumulation that would cause material degradation. This enables the converter to operate at optimal temperatures for high luminance while maintaining long-term reliability.
Solution Approach 2:
The invention creates local thermal management zones where heat is efficiently conducted away from the converter material that is most susceptible to degradation, while allowing other areas to maintain temperatures optimal for luminance generation. This localized thermal control preserves both brightness and reliability.
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 achieves efficient cooling, maintaining high luminance and long-term stability by distributing heat effectively across a large surface area, reducing average temperatures, and increasing the maximum allowed optical power of the light source while improving conversion efficiency and thermal stability.
Implementation Method 1
a converter fixed on one side of the carrying wheel, provided with fluorescent materials, or forming a fluorescent material, the converter converting impinging light into light having a different wave length by means of fluorescence
Implementation Method 2
the thermal conductivity of this material should be greater than 50 W/mK
Implementation Method 3
By the rotation, an airflow is generated which dissipates the heat to the environment
Implementation Method 4
a metallic solder connection for enhanced thermal conductivity and reflectivity
Implementation Method 5
increased emissivity of uncovered areas for effective heat dissipation
Data Source
AI summary
A converter arrangement for light sources with high luminance is provided that includes an axially pivotable carrying wheel and a converter fixed on one side of the carrying wheel. The converter includes fluorescent materials that convert impinging light into light having a different wave length and emits the light having the different wavelength. The ratio of the total area of the converter arrangement to the area enclosed by the outer boundary curve of the converter is at least 3, preferably at least 3.5, particularly preferably at least 4.5.