Phosphor Wheel Groove Design for Heat Dissipation and Balance
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Solution Overview
Problem
The phosphor wheel in projectors using laser diodes faces issues with heat dissipation and dynamic balance, leading to decreased light conversion efficiency and potential breakdown due to increased temperature, which affects the reliability and performance of the projection apparatus.
Innovation Solution
A phosphor wheel design featuring a groove on the disk plate with a reflection member to enhance heat dissipation and dynamic balance, utilizing the weight of the reflection member and phosphor layer to achieve balanced rotation and improved structural rigidity, along with heat-dissipating materials like metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the phosphor wheel rotates at high speed to convert blue light into yellow and green light, then the light conversion efficiency is improved, but the temperature increases causing the phosphor to burn out and breakdown
Solution Approach 1:
The phosphor wheel is segmented into multiple independent phosphor layers (yellow phosphor layer and green phosphor layer) that can be independently optimized for heat dissipation. Each layer is separated by reflective films, allowing independent thermal management and preventing heat accumulation that would occur in a monolithic structure.
Solution Approach 2:
Heat dissipation films are introduced as intermediary layers between the phosphor layers and the disk plate. These films have high thermal conductivity and act as thermal mediators, efficiently transferring heat away from the phosphor materials while maintaining the structural integrity of the wheel.
Solution Approach 3:
The patent changes the thermal parameters of the phosphor wheel system by selecting materials with specific thermal properties. The disk plate uses materials with high thermal conductivity, and the heat dissipation films are specifically chosen to optimize heat transfer, fundamentally changing the thermal management capability of the system.
2Speed
If the disk plate is made lighter to reduce rotational inertia, then the speed response is improved, but the dynamic balance and rigidity deteriorate
Solution Approach 1:
The patent introduces asymmetric weight distribution through the reflective films and phosphor layer configuration. By strategically placing these components, the center of gravity is precisely controlled to maintain dynamic balance during high-speed rotation, even with a lighter overall structure.
Solution Approach 2:
The disk plate undergoes preliminary dynamic balance adjustment during manufacturing. The weight distribution is pre-calculated and pre-adjusted to ensure optimal dynamic balance characteristics before the phosphor layers are applied, preventing vibration and instability during operation.
3Ease of manufacture
If the phosphor wheel structure is simplified to reduce manufacturing complexity, then the ease of manufacture is improved, but the heat dissipation capability and reliability deteriorate
Solution Approach 1:
The disk plate is designed with multi-functionality, serving as both the structural support and the heat dissipation pathway. The reflective films serve dual purposes: optical reflection for light conversion and thermal conduction for heat dissipation. This reduces the need for separate dedicated heat dissipation structures.
Solution Approach 2:
The phosphor layers are nested within the disk plate structure, with each phosphor layer embedded in its own reflective film cavity. This nested arrangement allows complex heat dissipation and optical pathways to be achieved within a compact, manufacturable form factor.
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 increases the reliability of the phosphor wheel by enhancing heat dissipation and dynamic balance, preventing breakdowns and maintaining light conversion efficiency, thus improving the overall performance of the projector.
Implementation Method 1
The reflection member is disposed in the groove to reflect the excitation beam
Implementation Method 2
The at least one phosphor layer is disposed at the annular irradiation zone to convert the excitation beam into at least one converted light beam
Implementation Method 3
promoting the heat exchange between the phosphor wheel and the external environment
Data Source
AI summary
The invention discloses a phosphor wheel, and a projector using the phosphor wheel. The projector includes an illumination system, a light valve, and a projection lens. The illumination system is used to provide an illumination beam. The light valve is disposed on a transmission path of the illumination beam and converts the illumination beam into an image beam. The projection lens is disposed on a transmission path of the image beam. The illumination system includes an excitation light source and a phosphor wheel. The excitation light source is used to provide an excitation beam to the phosphor wheel. The phosphor wheel includes a motor, a disk plate, a reflection member, and at least one phosphor layer. The motor has a shaft. The disk plate is connected to the shaft. In the invention, the phosphor wheel has better reliability and rigidity, and has the effect of enhancing heat dissipation.