Wave-Shaped Phosphor Wheel Structure for Heat and Strength
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Solution Overview
Problem
Conventional wheels face issues with structural weakness and inadequate heat dissipation, leading to deformation and reduced conversion efficiency, while ceramic substrates are brittle and prone to cracking, affecting reliability.
Innovation Solution
A wheel design featuring wave-shaped structures on the substrate, which enhance heat dissipation through turbulence and improve structural strength by incorporating slopes, reducing temperature and oscillation, and integrating convex and concave portions for enhanced airflow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If stamping or machining is used to form boss structures or groove structures on the heat dissipation substrate, then heat dissipation efficiency is improved, but the outer structure strength becomes weak and prone to deformation
Solution Approach 1:
The patent applies curvature by forming wave-shaped structures (convex and concave portions) on the heat dissipation substrate instead of traditional boss or groove structures. These curved wave structures enhance heat dissipation through turbulence while the continuous undulating form distributes stress more evenly, preventing the structural weakness and deformation associated with sharp-edged stamped features.
Solution Approach 2:
The patent changes the geometric parameters of the heat dissipation structures by using wave-shaped patterns with specific wavelengths and amplitudes. This parameter optimization allows the structures to achieve both effective heat dissipation and sufficient mechanical strength, resolving the contradiction between thermal performance and structural integrity.
2Temperature
If ceramic substrate is used to increase sintering temperature, then temperature resistance is improved, but the substrate becomes brittle and susceptible to hidden cracks
Solution Approach 1:
The patent employs a composite structure combining a metal substrate (providing ductility and crack resistance) with wave-shaped heat dissipation structures (providing enhanced thermal performance). This composite approach achieves high temperature resistance while maintaining reliability by avoiding the inherent brittleness of ceramic materials.
3Temperature
If heat dissipation boss is coated on ceramic substrate, then heat dissipation is improved, but the weight of substrate increases and wheel is more likely to have cracks
Solution Approach 1:
The patent segments the heat dissipation function from the structural substrate by forming integrated wave-shaped structures on the metal substrate. This eliminates the need for separate coated bosses, reducing additional weight and avoiding the crack propagation issues associated with coating-substrate interfaces on brittle ceramic materials.
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 wave-shaped structures effectively dissipate heat, enhance structural integrity, and improve conversion efficiency, reducing noise and motor damage, thereby extending product life and enhancing energy generation efficiency.
Implementation Method 1
the boss structures may produce turbulence or enhance convection during the high-speed rotation of the wheel
Implementation Method 2
the boss structures may produce turbulence or enhance convection during the high-speed rotation of the wheel
Data Source
AI summary
A wheel includes a substrate and an optical layer. The substrate includes an inner substrate and multiple wave-shaped structures. The inner substrate has a first surface and a second surface opposite to the first surface. The optical layer is disposed on the first surface. An excitation beam is incident toward the optical layer. The wave-shaped structures are connected to and disposed around the inner substrate. A first portion of the wave-shaped structures connected to the inner substrate include at least a slope. A projection device is provided.