Projector Light Source Groove Structure for Phosphor Rod Spacing

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Solution Overview

Problem

Existing light source devices in projectors face issues such as warpage due to heat, leading to potential breakage or loss of desired optical characteristics due to improper distance between the phosphor rod and light emitting element, or excessive contact pressure.

Innovation Solution

A light source device design that includes a light source substrate with a convex portion on its inner peripheral side, supporting a light guide member in a groove, and using a fixation part to maintain the distance between the light emitting element and the light guide member, preventing warpage and ensuring optimal optical characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the support substrate is heated by the light emitting element, then the light emitting element can operate, but warpage occurs in the support substrate causing excessive contact pressure on the phosphor rod

Engineering Contradiction:

Improvelight emitting element operationVSAvoidsupport substrate flatness

Core Design Contradiction:

PowerVSStability of the object's composition

Solution Approach 1:

The support substrate is divided into a first support portion and a second support portion separated by a groove. The light emitting element is disposed on the first support portion while the phosphor rod is disposed on the second support portion. This segmentation isolates the heat-generating light emitting element from the phosphor rod, preventing warpage-induced contact pressure and potential breakage of the phosphor rod.

Inventive Principle:

Principle #1Segmentation

2Productivity

If the distance between the phosphor rod and light emitting element is reduced to improve optical characteristics, then optical efficiency increases, but the phosphor rod and light emitting element may contact causing breakage

Engineering Contradiction:

Improveoptical characteristicsVSAvoidcomponent breakage resistance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The support substrate is segmented into first and second support portions by a groove, spatially separating the light emitting element and phosphor rod. This allows optimization of the distance between them for optimal optical characteristics while physically preventing contact and breakage through the groove separation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support substrate has different structural characteristics in different regions: the first support portion accommodates the light emitting element while the second support portion accommodates the phosphor rod. The groove creates a local structural difference that maintains optimal spacing and prevents harmful contact between components.

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If a contact member is added to hold the phosphor rod, then the phosphor rod position is stabilized, but excessive contact pressure may break the phosphor rod

Engineering Contradiction:

Improvephosphor rod positionVSAvoidphosphor rod integrity

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The support substrate is segmented into first and second support portions by a groove. The phosphor rod is disposed on the second support portion which is spatially separated from the light emitting element. This segmentation eliminates the need for additional contact members while maintaining phosphor rod position stability and preventing excessive contact pressure that could cause breakage.

Inventive Principle:

Principle #1Segmentation

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 maintains the distance and reduces warpage, preventing breakage and ensuring consistent optical performance by separating the light emitting element from the light guide member, thus achieving reliable operation.

Implementation Method 1

a light guide member configured to guide light emitted from the light emitting element of the light source unit

Methodology Applied

Scientific EffectLight guidance: Waveguide (optics)

Implementation Method 2

the convex portion is disposed on at least one of an opposed surface opposed to the first surface of the light source substrate and the first surface of the light source substrate to separate the light emitting element from the support member and the light guide member

Methodology Applied

Scientific EffectGeometric spacing: Geometry

Data Source

PatentUS12455411B2Light source device and projector

Publication Date: 2025.10.28 SEIKO EPSON CORP

AI summary

A light source device including: a support member includes a groove in which a light guide member is disposed, a light source substrate and the support member are in contact with each other with a convex portion, and the convex portion is disposed on at least one of an opposed surface opposed to a first surface of the light source substrate and the first surface of the light source substrate to separate a light emitting element from the support member and a light guide member.