Wavelength Conversion Module Turbulent Substrate Heat Dissipation
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Solution Overview
Problem
Current wavelength conversion modules in laser projectors face inefficiencies in heat dissipation due to limitations in the punching process and high costs associated with casting processes, while also generating noise during forced convection.
Innovation Solution
A wavelength conversion module design featuring a substrate with turbulent portions recessed on at least one surface, where the distribution area of these portions accounts for more than 60% of the exposure area, enhancing heat dissipation efficiency and reducing noise by increasing the heat dissipation area without increasing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If protrusions are formed on the aluminum substrate surface through punching process, then manufacturing cost is reduced, but heat dissipation efficiency is insufficient due to limited protrusion height (less than 0.5mm)
Solution Approach 1:
The patent transitions from two-dimensional surface protrusions to three-dimensional turbulent structures by forming recesses that extend into the substrate thickness. This dimensional change allows the turbulent portions to achieve greater effective height (up to 1.5mm or more) while maintaining compatibility with the punching process, thereby improving heat dissipation efficiency without sacrificing manufacturing cost advantages.
Solution Approach 2:
Instead of forming protrusions extending outward from the substrate surface, the patent inverts the approach by forming recesses that extend inward into the substrate. This inversion creates turbulent structures that achieve greater effective height for heat dissipation while remaining compatible with standard punching processes, resolving the contradiction between manufacturing simplicity and heat dissipation performance.
2Temperature
If casting process is used to manufacture aluminum substrate with three-dimensional fan blades, then heat dissipation efficiency is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces the expensive casting process with a simpler, more cost-effective punching process. By using standard punching equipment to create turbulent portions in the aluminum substrate, the invention achieves acceptable heat dissipation performance at a fraction of the manufacturing cost associated with casting three-dimensional fan blade structures.
Solution Approach 2:
The patent changes the key parameter from protrusion height to turbulent portion distribution and geometry. By optimizing the area ratio (60-90%), depth (0.5-1.5mm), and spatial arrangement of turbulent portions, the invention achieves heat dissipation efficiency comparable to or exceeding casting processes while maintaining the cost advantages of punching manufacturing.
3Temperature
If forced convection is used to improve heat dissipation, then heat dissipation efficiency is enhanced, but operation noise increases
Solution Approach 1:
The patent enables the wavelength conversion module to dissipate heat through self-generated natural convection currents. The turbulent portions create localized thermal patterns that drive natural air flow without requiring external forced convection mechanisms, thereby achieving effective heat dissipation while eliminating the noise associated with fans or forced air movement.
Solution Approach 2:
The patent replaces mechanical forced convection systems (such as fans) with a passive thermal convection system based on natural air currents. By designing the substrate with optimized turbulent portions, the invention harnesses natural buoyancy-driven flow to achieve heat dissipation without the mechanical noise generation inherent in forced convection systems.
4Ease of manufacture
If turbulent portions occupy small area on substrate, then manufacturing is simpler, but heat dissipation area is insufficient
Solution Approach 1:
The patent applies local quality optimization by concentrating turbulent portions in specific high-heat-generation zones of the substrate. By strategically positioning these structures where heat flux is highest, the invention maximizes heat dissipation effectiveness per unit area, allowing sufficient total heat dissipation area even when turbulent portions occupy only 60-90% of the substrate area.
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 significantly improves heat dissipation efficiency and reduces operation noise in wavelength conversion modules and projectors, maintaining cost competitiveness by using a compatible punching process.
Implementation Method 1
heat energy is thereby transmitted into the air through thermal convection
Implementation Method 2
create three-dimensional obstacles to generate forced convection
Data Source
AI summary
A wavelength conversion module and a projector including the wavelength conversion module are provided. The wavelength conversion module includes a substrate and a wavelength conversion layer. The substrate has a first surface and a second surface opposite to each other. The substrate includes a plurality of turbulent portions, and the turbulent portions are recessed in at least one of the first surface and the second surface. The wavelength conversion layer is disposed on the first surface of the substrate, and a distribution area of the turbulent portions accounts for more than 60% of an exposure area of the substrate. The wavelength conversion module and the projector provided by the disclosure exhibit favorable heat dissipation efficiency.