Diffuser Rod Exit-Surface Topology for Thermal Load Equalization
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Solution Overview
Problem
Existing illumination systems, particularly laser/phosphor projectors, face challenges in achieving high brightness with minimal optical degradation and component failure due to heat and power density issues, while maintaining a compact and lightweight design.
Innovation Solution
An optical assembly with a diffuser rod positioned at the exit plane of an integrator rod, featuring engineered diffusing surfaces to optimize power load equalization and angular uniformity, reducing thermal stress and optical component risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single channel light source is used, then the system can be more compact and lightweight, but the phosphor cooling must be scaled up and optical components are subject to higher stress
Solution Approach 1:
The patent divides the single light source into multiple channels (e.g., multiple laser sources or multiple phosphor wheels). Each channel processes a portion of the total light output requirement, distributing the thermal load and optical stress across multiple components rather than concentrating them in a single channel, thus resolving the contradiction between compactness and component stress resistance.
2Reliability
If multiple light source channels are used, then brightness decay resistance and safety margin improve, but space requirements and system complexity increase
Solution Approach 1:
The patent employs multiple phosphor wheels or optical components arranged in a nested or stacked configuration where components are positioned closely together in three-dimensional space. This nesting approach allows multiple light source channels to be integrated within a compact volume, reducing the space requirements while maintaining the reliability benefits of multiple channels.
3Duration of action of stationary object
If laser power towards the phosphor is distributed between channels, then brightness decay and phosphor assembly size are improved, but the system complexity increases
Solution Approach 1:
The patent combines multiple optical channels into a single integrated optical assembly where the light paths, phosphor wheels, and cooling systems are merged into one unified structure. This merging reduces the overall system complexity by eliminating the need for separate control and mounting systems for each channel, while still maintaining the distributed power architecture that extends phosphor assembly lifetime.
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
Enhances brightness and extends component lifetime by minimizing thermal stress and optical degradation, allowing for a more compact and efficient illumination system.
Implementation Method 1
the surface of the exit plane of the integrator rod is a diffusing surface
Implementation Method 2
Integrating rods make use of the total internal reflection effect (ref. Snell's law), and relies on the angular difference between incoming rays
Implementation Method 3
a lens assembly comprising at least one lens for focusing the light beam on the wavelength conversion element
Implementation Method 4
The phosphor is photochemically activated by high power input of blue laser light. The generated yellow phosphor light
Data Source
AI summary
There is provided an optical assembly for homogenizing a light beam and optimizing the wavelength conversion efficiency of an illumination system, the optical assembly being configured to be positioned in a beam path of the illumination system comprising a light source emitting the light beam, the optical assembly comprising a wavelength conversion element, a lens assembly comprising at least one lens for focusing the light beam on the wavelength conversion element an integrator rod comprising an entrance and an exit plane, wherein the exit plane of the integrator rod is configured to be reimaged on the wavelength conversion element via the lens assembly, wherein the surface of the exit plane of the integrator rod is a diffusing surface having an engineered topology optimized for the illumination system and with reduced thermal saturation and quenching limits.