Porous Wavelength Conversion Wheel for Phosphor Spot Cooling
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Solution Overview
Problem
Optical projectors face challenges in heat dissipation as brightness requirements increase, necessitating improved heat management for fluorescent materials and wheel components.
Innovation Solution
A wavelength conversion member comprising a rotating substrate with a phosphor layer and a ventilated or non-ventilated blade, where the blade's geometry and material design create micro-vortex effects to enhance air turbulence and heat dissipation, reducing the size and weight of the blade and the load on the driving unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the light source power is increased to meet brightness requirements, then the luminous output is improved, but the heat generation increases causing thermal decay of the phosphor layer
Solution Approach 1:
The blade is divided into multiple ventilation holes that segment the airflow path, creating multiple micro-vortex channels. This segmentation allows more efficient heat dissipation across the phosphor layer surface without increasing overall blade size or rotational load.
Solution Approach 2:
The blade is designed with a porous structure containing multiple ventilation holes. This porous configuration enables the blade to generate micro-vortex effects while maintaining structural integrity, effectively cooling the phosphor layer through enhanced air circulation without requiring excessive blade mass.
2Strength
If a conventional solid blade is used for ventilation, then the structural strength is sufficient, but the blade size and weight are large increasing the load on the driving unit
Solution Approach 1:
The blade employs a porous structure with controlled hole distribution that maintains sufficient structural strength while significantly reducing material usage. The ventilation holes are strategically positioned and sized to preserve blade rigidity where needed while removing excess weight that would increase driving unit load.
Solution Approach 2:
The blade exhibits local quality variations through non-uniform hole distribution and varying wall thickness in different regions. This allows the blade to maintain high strength-to-weight ratio by concentrating material where structural support is critical while creating ventilation channels in regions where weight reduction is prioritized.
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 effectively lowers the temperature of the light spot by at least 50°C compared to conventional designs, maintaining luminous efficiency and allowing for increased maximum operating power of the light source without heat decay.
Implementation Method 1
the overall geometry generates turbulence, and through holes of the ventilated blade simultaneously produce micro vortexes
Implementation Method 2
the overall geometry generates turbulence, and through holes of the ventilated blade simultaneously produce micro vortexes
Implementation Method 3
a phosphor layer, and a ventilated blade. The substrate is configured to rotate based on an axis. The phosphor layer is disposed on the substrate
Data Source
AI summary
A wavelength conversion member includes a substrate, a phosphor layer, and a ventilated blade. The substrate is configured to rotate based on an axis. The phosphor layer is disposed on the substrate. The ventilated blade is disposed on the substrate and has a pore density between 10 ppi and 500 ppi or a volume porosity between 5% and 95%.