LED Heat Sink Segmentation for Projector Thermal Management
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Solution Overview
Problem
Image projectors using LEDs face challenges in controlling the junction temperatures of LEDs, which affects light intensity and reliability, particularly since existing solutions fail to efficiently manage the different temperature requirements of red, green, and blue LEDs.
Innovation Solution
The use of separate heat sinks and a cooling fan system that directs airflow independently over each LED type, with an air gap between thermal subsystems to optimize heat dissipation and reduce heat exchange, allowing for independent volume selection of heat sinks to achieve desired junction temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate heat sinks are used for red LED and green/blue LEDs, then junction temperature control is improved, but device complexity increases
Solution Approach 1:
The heat dissipation system is segmented into separate heat sinks for different LED types. The patent divides the thermal management system into at least two distinct heat sinks: one for the red LED and another for the green and blue LEDs. This segmentation allows independent temperature control for each LED type, addressing their different thermal requirements and improving junction temperature control while managing the complexity through modular design.
2Measurement precision
If independent airflow paths are used for each LED type, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The airflow path is segmented into separate channels for different LED types. The patent configures the housing to include distinct air intake and exhaust paths that direct airflow independently to each heat sink. This segmentation enables precise temperature control for each LED type by providing dedicated cooling airflow, while the integrated housing design manages the overall complexity.
3Productivity
If heat sinks are optimized for specific LED types, then heat dissipation efficiency is improved, but volume of heat sinks increases
Solution Approach 1:
Each heat sink is designed with local quality optimized for its specific LED type. The patent specifies that the first heat sink for the red LED and the second heat sink for the green and blue LEDs have different configurations tailored to their respective thermal characteristics. This local optimization improves heat dissipation efficiency for each LED type while the overall compact integration manages the total volume.
4Loss of energy
If air gap is introduced between thermal subsystems, then heat exchange reduction is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates unwanted heat exchange between thermal subsystems by introducing air gaps between the heat sinks. This separation prevents thermal interference between the red LED and green/blue LED subsystems, ensuring independent temperature control. The air gap acts as a thermal isolation layer, removing the harmful thermal coupling while the integrated housing manages the overall structure.
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 approach effectively controls the junction temperatures of LEDs, enhancing light intensity and reliability by optimizing heat dissipation for each color LED, reducing the overall volume of heat sinks and air flow requirements.
Implementation Method 1
The first heat sinks are configured to dissipate heat generated by the first LEDs. The second heat sinks are configured to dissipate heat generated by the one or more second LEDs.
Implementation Method 2
each first heat sink is thermally coupled to a first circuit board. Each second heat sink is thermally coupled to a second circuit board.
Implementation Method 3
A cooling fan directs air flow over the first heat sinks and the second heat sinks.
Implementation Method 4
The air gap may reduce the exchange of heat between the thermal subsystems.
Data Source
AI summary
According to certain embodiments, an apparatus for cooling light emitting diodes (LEDs) in projectors includes one or more first LEDs, one or more first heat sinks, one or more second LEDs, and one or more second heat sinks. The first LEDs are configured to generate light, and each first LED has a first desired junction temperature. The first heat sinks are configured to dissipate heat generated by the first LEDs. The second LEDs are configured to generate light, and each second LED has a second desired junction temperature that is higher than the first desired junction temperature. The second heat sinks are configured to dissipate heat generated by the one or more second LEDs. A cooling fan directs air flow over the first heat sinks and the second heat sinks, and an exhaust vent enables the air flow over the first heat sinks and the second heat sinks.