Projector Light Assembly LED Heat Sink Adaptor
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Solution Overview
Problem
High-intensity projectors rely on expensive and short-lived Xenon-Plasma HID bulbs, which produce excessive heat and contain hazardous materials, posing safety risks and operational challenges.
Innovation Solution
A light assembly for projectors that includes an LED emitter with a heat sink and cooling fan, mechanically coupled to the projector's bulb mount, using an adaptor to adjust the LED's position and a lens to collimate light, replacing traditional bulbs with energy-efficient LEDs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If Xenon-Plasma HID bulbs are used to produce high-intensity light, then illumination intensity is improved, but lifespan deteriorates and operational cost increases
Solution Approach 1:
The patent transitions from Xenon-Plasma HID bulb technology to LED technology, fundamentally changing the light generation mechanism. LEDs produce comparable illumination intensity (20,000-34,000 lumens) but with vastly improved lifespan (50,000+ hours vs. 6-16 weeks), directly resolving the contradiction between light intensity and operational duration
Solution Approach 2:
The patent replaces the thermal-mechanical breakdown process of HID bulbs with the electroluminescence mechanism of LEDs. This substitution eliminates the gradual degradation inherent in arc discharge and filament-based systems, achieving both high intensity and extended lifespan simultaneously
2Power
If high-wattage bulbs are used to achieve high lumen output, then power is improved, but heat generation worsens
Solution Approach 1:
The patent changes the fundamental operating parameters from 3,000-5,000 watt HID bulbs to LED arrays that achieve equivalent lumen output with dramatically reduced power consumption. The LED technology converts electrical energy to light with much higher efficiency, producing minimal waste heat compared to the thermal-mechanical process of HID bulbs
Solution Approach 2:
The patent addresses the heat management challenge by designing a heat sink system with cooling fans that efficiently dissipates the relatively small amount of heat generated by LEDs. This converts the potential harmful heat into a manageable parameter, unlike the excessive heat inherently produced by high-wattage HID bulbs
3Illumination intensity
If Xenon-Plasma HID bulbs are used for high-intensity projection, then illumination intensity is improved, but safety deteriorates due to hazardous materials and explosion risk
Solution Approach 1:
The patent extracts and eliminates the hazardous elements (mercury, high-voltage arc discharge, explosion-prone glass envelope) inherent in Xenon-Plasma HID bulbs. The LED-based system achieves the same illumination intensity without these dangerous components, fundamentally improving safety while maintaining performance
Solution Approach 2:
The patent replaces the fragile, hazardous HID bulb with a more robust LED system that, while requiring heat management, eliminates the explosion and mercury contamination risks. The solid-state LED construction is inherently safer and more reliable despite the different failure modes
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 extends the lifespan of projector lighting, reduces operational costs, eliminates hazardous materials, and provides a safer, more efficient illumination solution for high-lumen applications.
Implementation Method 1
a cooling fan configured to generate airflow across the heat sink
Implementation Method 2
a heat sink configured to dissipate heat from the primary LED Emitter mounting plate
Implementation Method 3
a lens configured to collimate light emitted from the at least one LED
Data Source
AI summary
In one aspect, a light assembly is configured to be installed in a movie theater projector and includes an adaptor configured to mechanically couple to a bulb mount of the projector, a primary LED Emitter mounting plate and LEDs attached to the primary LED Emitter mounting plate. The light assembly also includes a heat sink configured to dissipate heat from the primary LED Emitter mounting plate, a cooling fan configured to generate airflow across the heat sink, a lens mounting plate and a lens configured to collimate light emitted from the LEDs, where the lens is disposed over the lens mounting plate. The light assembly also includes an attachment assembly configured to attach the lens mounting plate to the primary LED Emitter mounting plate. The adaptor may be manipulated to adjust a distance between the bulb mount of the movie theater projector and the primary LED Emitter mounting plate.