Dichroic Color Mixing Flag Geometry for Thermal Shock

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Solution Overview

Problem

Dichroic color mixing flags used in high-powered multiparameter lighting fixtures are prone to thermal shock and cracking due to increased intensity, and replacing the borosilicate substrate with lower expansion materials like quartz is costly and not readily available.

Innovation Solution

Constructing dichroic color mixing flags with alternative geometries such as circular, elliptical, or oval shapes to improve thermal shock tolerance, allowing for greater expansion without changing the substrate material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If high-powered light sources are used to increase light output intensity, then illumination intensity is improved, but thermal shock and cracking of dichroic color mixing flags worsen

Engineering Contradiction:

Improvelight output intensityVSAvoidthermal shock tolerance

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The patent applies spheroidality by changing the flag geometry from traditional rectangular shapes to circular, elliptical, or oval shapes. This curvature allows for more uniform thermal distribution and expansion patterns, reducing thermal stress concentration points that cause cracking in rectangular flags under high-powered light sources

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If borosilicate substrate is replaced with lower expansion materials like quartz to improve thermal shock tolerance, then thermal shock tolerance is improved, but manufacturing cost and availability worsen

Engineering Contradiction:

Improvethermal shock toleranceVSAvoidmanufacturing cost and availability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by modifying the geometric parameters of the flag (shape, dimensions, thickness distribution) rather than changing the material substrate. This allows maintaining the cost-effective borosilicate glass substrate while achieving improved thermal shock tolerance through optimized circular, elliptical, or oval geometries that distribute thermal stress more evenly

Inventive Principle:

Principle #35Parameter changes

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 new geometries significantly enhance the thermal shock tolerance of dichroic color mixing flags, preventing cracking when used with high-powered light sources without the need for expensive quartz substrates.

Implementation Method 1

The dichroic filters transmit light incident thereon and reflect the complement of the color of the transmitted beam

Methodology Applied

Scientific EffectDichroic filter: Dichroic Filter

Implementation Method 2

allowing for greater expansion without changing the substrate material

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS7896525B2Heat resistant color mixing flag for a multiparameter light

Publication Date: 2011.03.01 ELECTRONIC THEATRE CONTROLS INC

AI summary

A dichroic mixing flag for a multiparameter light is constructed that greatly improves the thermal shock tolerance of the flag and avoids having to use a more costly substrate material. The dichroic color mixing flag may be substantially circular in shape. The dichroic color mixing flag may be fixed to a mechanical component so that the flag cannot rotate with respect to the mechanical component. The dichroic color mixing flag may be fixed to the mechanical component so that the mechanical component can move the dichroic color mixing flag without moving any other dichroic color mixing flag.