Projector LED Light Assembly Thermal Management

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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 increasing operational costs.

Innovation Solution

A light assembly for projectors that includes an LED emitter plate, a cooling assembly, and a lens system with adjustable lenses to collimate light, mechanically coupling to existing bulb mounts and using a separate control system for operation, replacing traditional bulbs with energy-efficient LEDs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If Xenon-Plasma HID bulbs are used to produce high-intensity light, then illumination intensity is improved, but temperature increases and lifespan decreases

Engineering Contradiction:
Improvelight intensityVSAvoidheat production
Core Design Contradiction:
Illumination intensityVSTemperature

Solution Approach 1:

The patent transitions from Xenon-Plasma HID bulb technology to LED technology, fundamentally changing the light generation mechanism. LEDs produce light through electroluminescence rather than thermal radiation or plasma discharge, operating at significantly lower temperatures while maintaining or exceeding the illumination intensity of traditional bulbs. This parameter change in the light source technology resolves the contradiction between high light output and excessive heat generation.

Inventive Principle:
Principle #35Parameter changes

2Illumination intensity

If Xenon-Plasma HID bulbs are used to produce high-intensity light, then illumination intensity is improved, but duration of action decreases

Engineering Contradiction:
Improvelight intensityVSAvoidbulb lifespan
Core Design Contradiction:
Illumination intensityVSDuration of action of moving object

Solution Approach 1:

The patent employs a fundamental technology parameter change by replacing short-lived Xenon-Plasma HID bulbs with long-lived LED light sources. LEDs have no filament to burn out and no plasma arc to degrade, providing a service life measured in tens of thousands of hours compared to the limited lifespan of traditional projector bulbs. This parameter change in light source technology simultaneously achieves high illumination intensity and extended operational duration.

Inventive Principle:
Principle #35Parameter changes

3Illumination intensity

If Xenon-Plasma HID bulbs are used, then illumination intensity is improved, but harmful factors increase due to hazardous materials and explosion risk

Engineering Contradiction:
Improvelight intensityVSAvoidsafety hazards
Core Design Contradiction:
Illumination intensityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces hazardous, expensive, and fragile Xenon-Plasma HID bulbs with robust, safe, and economical LED light sources. LEDs contain no mercury or other hazardous materials, eliminate explosion risks entirely, and are mechanically more durable. This substitution removes the harmful factors associated with traditional bulbs while maintaining the required illumination intensity for projector operation.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

4Illumination intensity

If Xenon-Plasma HID bulbs are used to produce high-intensity light, then illumination intensity is improved, but use of energy increases

Engineering Contradiction:
Improvelight intensityVSAvoidpower consumption
Core Design Contradiction:
Illumination intensityVSUse of energy by moving object

Solution Approach 1:

The patent implements a parameter change in the light generation mechanism by adopting LED technology. LEDs convert electrical energy to light with much higher efficiency than Xenon-Plasma HID bulbs, which waste significant energy as heat. The LED-based light source delivers equal or superior illumination intensity while consuming a fraction of the electrical power, directly resolving the contradiction between light output and energy consumption.

Inventive Principle:
Principle #35Parameter changes

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 ensures safer operation by using energy-efficient LEDs with adjustable light collimation for high-intensity applications.

Implementation Method 1

an LED emitter plate. At least one LED is directly or indirectly attached to the LED emitter plate and configured to emit a beam of light

Methodology Applied
Scientific EffectElectroluminescence: Electroluminescence

Implementation Method 2

a cooling assembly configured to dissipate heat from the LED emitter plate

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a cooling assembly configured to dissipate heat from the LED emitter plate

Methodology Applied
Scientific EffectConvection: Convection

Implementation Method 4

a concave adjustor with a concave lens configured to spread the beam emitted from the at least one LED

Methodology Applied
Scientific EffectRefraction: Refraction

Implementation Method 5

a convex adjustor with a convex lens configured to collimate light received from the concave lens

Methodology Applied
Scientific EffectRefraction: Refraction

Data Source

PatentUS10698306B2Light assembly for a projector
Publication Date: 2020.06.30 EPIC UNIVERSAL TECHNOLOGIES LLC
  • US10698306B2 patent drawing
  • US10698306B2 patent drawing
  • US10698306B2 patent drawing

AI summary

In one aspect, a light assembly configured to be installed in a movie theatre projector includes an emitter housing with an LED emitter plate that emits a beam of light and a lens assembly. The light assembly also includes a cooling assembly configured to dissipate heat from the LED emitter plate. The a cooling assembly includes a cooling fluid jacket coupled to the LED emitter plate, where the cooling fluid jacket comprises a metal layer enclosing a hollow path for cooling fluid, and where the cooling fluid jacket is configured to allow the cooling fluid to pass through cooling fluid jacket, thereby drawing heat from the LED emitter plate. The light assembly also includes a heat sink and a cooling fan. The cooling assembly further includes cooling sections to cool the cooling fluid that flows out of the cooling fluid jacket.