Wavelength Conversion Module Heat Dissipation Through Holes

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Solution Overview

Problem

Digital light processing projectors using color wheels face overheating issues due to heat transfer from phosphor excitation, leading to motor malfunction and reduced lifespan, with existing solutions like additional heat dissipation devices increasing costs and noise.

Innovation Solution

A wavelength conversion module with a wheel having a wavelength conversion area surrounded by a heat dissipation area, featuring through holes that connect the surfaces and satisfy a specific resonance frequency equation, to reduce noise and enhance heat dissipation, thereby preventing motor overheating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heat dissipation devices are installed near the color wheel to address overheating, then heat dissipation performance is improved, but device complexity and cost increase

Engineering Contradiction:

Improveheat dissipation performanceVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the heat dissipation function with the color wheel structure itself by creating through-holes directly in the color wheel. This eliminates the need for separate heat dissipation devices, as the color wheel becomes both the functional component for wavelength conversion and the heat dissipation structure. The through-holes allow heat to be conducted away from the phosphor coating directly through the color wheel body, integrating thermal management into the existing component rather than adding external devices.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The color wheel is designed to serve multiple functions simultaneously: wavelength conversion (its primary function) and heat dissipation (an additional function). By incorporating through-holes in the color wheel structure, the same component that converts light wavelength also acts as a heat dissipation pathway, reducing the need for dedicated heat dissipation components and simplifying the overall system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If dissipation fan efficiency is increased to address overheating, then heat dissipation performance is improved, but noise increases

Engineering Contradiction:

Improveheat dissipation performanceVSAvoidnoise

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the mechanical fan-based heat dissipation system with a passive heat dissipation structure using through-holes in the color wheel. Instead of using a rotating fan that generates noise to force air circulation, the design relies on thermal conduction through the color wheel body and natural convection currents created by temperature differences, eliminating the noisy mechanical component while maintaining effective heat dissipation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If motor speed is increased to improve projector performance, then productivity is improved, but heat generation increases causing overheating

Engineering Contradiction:

Improveprojector performanceVSAvoidmotor temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent converts the harmful heat generated by high-speed motor operation into a beneficial outcome by using it to drive natural convection currents through the color wheel's through-holes. The heat that would otherwise cause overheating is instead utilized to create thermal convection that actively removes heat from the system, turning the harmful thermal byproduct of high-performance operation into a useful heat dissipation mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 effectively reduces noise and heat transfer, extending the lifespan of the motor and projector components while minimizing costs and noise pollution.

Implementation Method 1

the blue laser excites the phosphor when projected on the color wheel and produces color lights of higher wavelength, such as green light and red light

Methodology Applied

Scientific EffectPhosphorescence: Phosphorescence

Implementation Method 2

the heat is often transferred to the motor along the wheel

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

increase the heat dissipation efficiency of the dissipation fan

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 4

the resonance frequency f, the diameter d, and the distance D satisfy the relation: f = c/(2*t*sqrt(L/(L+t)))

Methodology Applied

Scientific EffectResonance: Resonance

Data Source

PatentUS10816881B2Wavelength conversion module

Publication Date: 2020.10.27 QISDA CORP

AI summary

A wavelength conversion module for being disposed on a light path of light of a projector is provided. The wavelength conversion module includes a driving module and a wheel. The wheel has an axial hole, a heat dissipation area and a complementary dissipation area. The axial hole is connected to the driving module, the heat dissipation area surrounds the axial hole, and the wavelength conversion area surrounds the heat dissipation area and the light is projected to the wavelength conversion area. The heat dissipation area includes a plurality of through holes penetrating through the wheel, in which the plurality of through holes has a plurality of first through holes and a plurality of second through holes. The plurality of first through holes is arranged circularly on the wheel around the axial hole. Each of the plurality of second through holes is arranged between every two adjacent first through holes.