Projection Wheel Protruding Structures Bonding
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Solution Overview
Problem
Existing wheels, such as phosphor wheels, face issues with structural reliability due to small bonding areas between clamping and balance components, inadequate adhesive curing, and low temperature resistance, leading to balance component detachment at high speeds, increased vibration, and noise, which can damage driving components and affect wheel functionality.
Innovation Solution
The wheel design incorporates a clamping element with protruding structures and a balance component with adhesive covering both, increasing bonding area and strength, and includes recessed structures on the clamping element for improved heat dissipation and adhesive bonding, enhancing structural reliability and heat dissipation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flat surface is used for bonding the balance component to the clamping element, then the structure is simple, but the bonding area is small and bonding strength is insufficient
Solution Approach 1:
The flat bonding surface is segmented into multiple protruding structures (first protruding structure, second protruding structure, etc.), which divide the bonding area into multiple regions. This segmentation increases the total bonding area between the clamping element and balance component, thereby improving bonding strength without significantly complicating the overall structure.
Solution Approach 2:
The bonding interface is extended from a two-dimensional flat surface to a three-dimensional structure with multiple protrusions. By adding vertical dimension (height of protruding structures) and spatial distribution (multiple protrusions arranged in specific patterns), the bonding area is substantially increased while maintaining reasonable structural complexity.
2Strength
If adhesive is applied under the balance component, then bonding can be achieved, but the curing beam cannot irradiate the adhesive completely resulting in inadequate curing
Solution Approach 1:
The bonding structure is segmented into protruding regions and gaps, allowing the curing beam to access adhesive in multiple locations. The gaps between protruding structures create pathways for UV light to reach and cure adhesive that would otherwise be hidden, ensuring complete curing of the adhesive layer.
Solution Approach 2:
The protruding structures act as intermediaries that facilitate the curing process. They create a topography that allows UV light to reach adhesive in multiple zones, effectively mediating between the curing beam and the adhesive to ensure complete curing throughout the bonding interface.
3Temperature
If the clamping element has a smooth surface, then manufacturing is easy, but heat dissipation efficiency is low and adhesive deteriorates at high temperature
Solution Approach 1:
The smooth surface is segmented into multiple protruding structures with gaps between them. This segmentation increases the surface area for heat dissipation and creates turbulent flow paths for coolant or air, improving heat transfer efficiency without requiring complex manufacturing processes.
Solution Approach 2:
The clamping element incorporates a porous-like structure with gaps and protrusions that increase surface area and promote turbulent flow. This structure enhances convective heat transfer and allows better thermal management, keeping the adhesive within its operating temperature range.
4Reliability
If the balance component is bonded to a flat surface, then assembly is simple, but the balance component falls off during high-speed rotation
Solution Approach 1:
The bonding interface is segmented into multiple protruding structures distributed across the clamping element surface. This segmentation creates multiple bonding points that distribute centrifugal forces during rotation, preventing the balance component from detaching even at high speeds while maintaining reasonable structural complexity.
Solution Approach 2:
The protruding structures have curved surfaces that provide better contact area and mechanical interlocking with the balance component. The curved geometry enhances bonding strength and resistance to centrifugal forces during rotation, improving component retention reliability.
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 enhanced bonding and heat dissipation improve the wheel's structural reliability and projection quality, reducing the risk of component detachment and increasing the service life of the adhesive, resulting in better performance and competitiveness for projection devices.
Implementation Method 1
The balance component includes a balance substance and an adhesive. The balance substance is disposed on the protruding structure, and the adhesive covers the balance substance and the protruding structure to fix the balance component on the clamping element.
Implementation Method 2
the protruding structure also has a turbulence function, which can effectively improve the heat dissipation efficiency of the wheel of the disclosure
Implementation Method 3
The position where the existing clamping component filled with the balance component is a flat surface. Therefore, the bonding area for the adhesive material (such as ultraviolet curing adhesive) that adheres the balance component to the clamping element is small. Besides, it is difficult to cure the adhesive entirely since the curing beam (such as ultraviolet light) is not easily irradiated to the adhesive covered by the balance component.
Data Source
AI summary
A wheel provided by the disclosure includes a substrate, a driving component, a clamping element and a balance component. The driving component is connected to the substrate, and is configured to drive the substrate to rotate about the axis of the driving component as the central axis. The clamping element is arranged on the substrate along the axis, and the clamping element includes a plurality of protruding structures. The balance component includes a balance substance and an adhesive. The balance substance is arranged on the protruding structure, and the adhesive covers the balance substance and the protruding structure to fix the balance component on the clamping element. The wheel and projection device provided by the disclosure have better structural reliability and heat dissipation efficiency.