Phosphor Wheel Recess Design for Heat Dissipation
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Solution Overview
Problem
Conventional phosphor wheels in DLP projectors face issues with heat dissipation, leading to decreased optical efficiency due to high temperatures, which can cause the phosphor layer to burn, and existing solutions that attempt to reduce temperature through hole configurations compromise dynamic balance and increase manufacturing complexity.
Innovation Solution
A phosphor wheel design featuring a rotating disk with recess portions on its surface, which disturbs air to enhance heat dissipation without altering the disk's configuration dramatically, maintaining stability and increasing the heat dissipating area, thereby reducing the temperature of the wavelength converting layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the phosphor layer is disposed in an enclosed cavity to prevent dust entry, then the phosphor layer is protected from dust contamination, but the temperature increases causing decreased optical efficiency and potential phosphor layer burnout
Solution Approach 1:
A heat dissipation plate is introduced as an intermediary component between the light source and the phosphor layer. The plate conducts heat away from the phosphor layer through its thermal conductivity, acting as a thermal mediator that separates the heat generation source from the temperature-sensitive phosphor material, thereby maintaining lower operating temperatures while preserving the enclosed protective cavity structure
Solution Approach 2:
The thermal parameters of the cavity environment are changed by introducing active heat dissipation mechanisms including fans for forced air convection and thermoelectric cooling elements. These parameter changes transform the thermal state of the cavity from passive heat accumulation to active heat removal, enabling temperature control that prevents phosphor degradation while maintaining the sealed protective environment
2Temperature
If several holes or extra structures are disposed on the plates to accelerate heat dissipation, then the heat dissipation efficiency is improved, but the dynamic balance of the rotatable plate becomes unstable and manufacturing complexity increases
Solution Approach 1:
The heat dissipation function is segmented from the rotating phosphor wheel assembly and transferred to a separate stationary heat dissipation plate. This segmentation allows the rotating component to maintain its simple, balanced structure for stable operation, while the stationary component handles the complex heat dissipation functions including fin structures and active cooling elements, thus resolving the conflict between heat dissipation efficiency and rotational dynamic balance
Solution Approach 2:
A stationary heat dissipation plate serves as an intermediary thermal management component that interfaces with the rotating phosphor wheel without becoming part of the rotating assembly. This mediator absorbs and dissipates heat generated during operation, enabling effective thermal management while preserving the rotational simplicity and dynamic balance of the phosphor wheel itself
3Temperature
If several holes or extra structures are disposed on the plates to accelerate heat dissipation, then the heat dissipation efficiency is improved, but the heat dissipating region of the plate is decreased and manufacturing complexity increases
Solution Approach 1:
The device is segmented into a simple rotating phosphor wheel assembly and a separate stationary heat dissipation plate with complex thermal management features. This segmentation concentrates the manufacturing complexity in the stationary component where it does not affect the rotational dynamics, while the rotating component maintains simplicity for easy fabrication and balanced operation
Solution Approach 2:
The stationary heat dissipation plate acts as an intermediary component that absorbs the manufacturing complexity of thermal management features. By placing fins, channels, and active cooling elements in the stationary plate rather than the rotating wheel, the design enables complex heat dissipation functionality while keeping the rotating assembly simple and easy to manufacture
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 design effectively decreases the temperature of the wavelength converting layer by 10°C, maintains dynamic balance, and increases the heat dissipating region, preventing phosphor layer burnout and improving overall projector performance.
Implementation Method 1
the recess portion is formed on the second surface or the non-coating region of the first surface... when the plate rotates such that the recess portion disturbs the air to accelerate the heat dissipation
Implementation Method 2
The wavelength converting layer has a first wavelength converting material for converting the light beam into a first wavelength light beam and a second wavelength converting material for converting the light beam into a second wavelength light beam
Data Source
AI summary
A phosphor wheel includes a rotating disk and a wavelength converting layer. The rotating disk has a first surface and a second surface opposite to the first surface, in which the first surface forms a coating region and a non-coating region. The wavelength converting layer is formed on the coating region of the first surface for converting a light wavelength of a light beam. In addition, an embodiment of the invention discloses a projection device having the phosphor wheel. When the rotating disk of the phosphor wheel rotates, the recess portion may disturb the air around the phosphor wheel such that the temperature of the wavelength converting layer may be effectively decreased. Simultaneously, the rotating disk has a stable dynamic balance and the rotating disk has a larger heat dissipating region because the recess portion is disposed on the rotating disk.