Light Converter with Motorless Heat Dissipation for Projectors

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Solution Overview

Problem

Existing projector technologies face challenges in cooling the fluorescent body without increasing size or reducing reliability, particularly in non-rotating methods that suffer from heat generation and decreased optical conversion efficiency.

Innovation Solution

A light converter with a fluorescent body bonded to a first light-collecting lens, where the lens surface is adhered to a heat-dissipating member around the bonded region, allowing for motorless heat dissipation and improved reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If air is interposed between the light-collecting lens and the substrate to prevent dust adherence, then dust-proofing is improved, but heat dissipation capability deteriorates

Engineering Contradiction:
Improvedust-proofingVSAvoidheat dissipation capability
Core Design Contradiction:
ReliabilityVSTemperature

Solution Approach 1:

A dust-proof film is introduced as an intermediary layer between the light-collecting lens and the substrate. This thin film maintains close contact to ensure effective heat dissipation while preventing dust particles from adhering to the optical surfaces, thus resolving the contradiction between dust-proofing and heat dissipation

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

A flexible dust-proof film is used to cover the light-collecting lens and fluorescent body. The film's thin structure allows heat to pass through effectively while providing a protective barrier against dust contamination, maintaining both optical efficiency and thermal management

Inventive Principle:
Principle #30Flexible shells and thin films

2Temperature

If a motor-driven fluorescent wheel is used for heat dissipation, then cooling effectiveness is improved, but device complexity and noise increase

Engineering Contradiction:
Improvecooling effectivenessVSAvoidmotor and rotation mechanism
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The motor and rotation mechanism are completely removed from the system. Instead of rotating the fluorescent wheel, the patent uses stationary fluorescent bodies with enhanced thermal contact to the substrate, extracting the unnecessary mechanical components while maintaining cooling effectiveness

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The fluorescent body itself serves the dual function of light conversion and heat dissipation by maintaining direct thermal contact with the heat sink substrate. The system uses the inherent thermal properties of the materials rather than active mechanical cooling, allowing the structure to self-regulate temperature

Inventive Principle:
Principle #25Self-service

3Device complexity

If the fluorescent body is kept stationary to reduce mechanical complexity, then device complexity is reduced, but heat dissipation becomes less effective

Engineering Contradiction:
Improvemechanical structureVSAvoidheat dissipation
Core Design Contradiction:
Device complexityVSTemperature

Solution Approach 1:

The patent applies different thermal management strategies to different regions: the fluorescent body maintains direct thermal contact with the substrate in critical heat-generating areas, while air circulation or heat sinks manage heat in less critical regions, allowing effective stationary heat dissipation

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The system uses composite structures combining materials with different thermal properties - high thermal conductivity materials at the fluorescent body-substrate interface for efficient heat transfer, and heat sink materials with large surface areas for heat dissipation, achieving effective cooling without mechanical movement

Inventive Principle:
Principle #40Composite materials

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 configuration enables effective cooling of the fluorescent body in a motorless manner, reducing size and enhancing reliability while maintaining luminance and optical efficiency.

Implementation Method 1

a fluorescent body that is excited by excitation light

Methodology Applied
Scientific EffectFluorescence: Fluorescence

Implementation Method 2

a heat-dissipating member to which the lens surface is adhered at least around a region to which the fluorescent body is bonded

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10775687B2Light converter and light source unit, and projector
Publication Date: 2020.09.15 SONY GROUP CORP
  • US10775687B2 patent drawing
  • US10775687B2 patent drawing
  • US10775687B2 patent drawing

AI summary

The invention aims to provide small-sized and highly-reliable light converter and light source unit, as well as a projector each of which makes it possible to cool down heat generated in a fluorescent body in a motorless manner. A light converter of the disclosure includes a fluorescent body that is excited by excitation light; a first light-collecting lens that has a lens surface to which the fluorescent body is bonded, and causes the excitation light to enter the fluorescent body; and a heat-dissipating member to which the lens surface is adhered at least around a region to which the fluorescent body is bonded.