JP2005085490A - Light source and its manufacturing method and projection type display device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To realize a high luminance of an LED as a light source of a projector. <P>SOLUTION: In a light source device 2 in which a solid light source 11 is installed on a cooling pipe 32, a wire rod 26 which is bent and deformed in a cotton shape (steel wool etc.) is filled in the cooling pipe. Therefore, the heat of the solid light source 11 can be transmitted by a large surface area of the wire rod to a cooling fluid F flowing in a pipe. Further, since the flow of the fluid F becomes turbulent flow due to the wire rod 26, the contact opportunity of the fluid F with the inner wall of the pipe and the wire rod 26 increases and the fluid F is agitated, therefore, the whole fluid can be contributed to cooling. Furthermore, since the member performing heat conduction is made of the flexible wire rod 26, when, for instance, the solid light source 11 is installed on the pipe, the flat part 37 for installation of the light source can be formed easily by pressurizing the surface of this pipe. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a light source device, a manufacturing method thereof, and a projection display device including the light source device, and more particularly to a chip cooling mechanism using a cooling fluid.

In conventional projectors (projection display devices), a halogen lamp has been used as a light source in the past, and a high-pressure mercury lamp (UHP) having high luminance and high efficiency has been used in recent years. A light source using UHP, which is a discharge lamp, requires a high-voltage power circuit, is large and heavy, and hinders the reduction in size and weight of the projector. Further, although it has a longer life than a halogen lamp, it still has a short life, and it is almost impossible to control the light source (fast lighting, extinguishing, modulation), and it takes a long time to start up.
In recent years, therefore, LEDs have attracted attention as a new light source. LEDs are ultra-compact, ultra-light, and have a long life. In addition, by controlling the drive current, it is possible to freely turn on / off and adjust the amount of emitted light. In this respect, it is also promising as a light source for projectors, and application development has already started for small and portable small screen projectors.

  However, at present, it is difficult to obtain sufficient luminance with a projector using an LED as a light source. This is because a sufficient current cannot flow through the chip due to the heat generated by the LED chip. For this reason, when the LED is applied to a light source such as a projector, a means for efficiently cooling the LED with a cooling fluid or the like is required.

Conventionally, the following is known as a cooling mechanism of a device using a fluid.
(1) A U-shaped duct for circulating a cooling fluid is provided inside the heat conductor that supports the heating element (Patent Document 1).
(2) A power device is provided on a flow path for circulating a cooling fluid through a partition, and a fin structure is provided on the flow path side of the partition (Patent Document 2).
(3) In a heat sink having a flow path for cooling fluid circulation, a granular heat conductor is immersed in the flow path (Patent Document 3).
JP 7-68840 A JP 2003-8264 A JP 2000-82769 A

However, the conventional cooling mechanisms (1) to (3) described above have the following problems.
(1) Since the LED generates a large amount of heat from a small area, heat can be transferred only to a portion of the fluid flowing in the duct that is close to the wall. For this reason, most fluid flows through the duct as it is without contributing to cooling.
(2) When fins are provided on small parts, it is necessary to thin the fins and narrow the intervals. However, such fins are accurately formed on the back surface of a small member of about several millimeters square such as an LED. It is extremely difficult.
(3) In order to prevent the heat conductor from moving due to the flow of the cooling fluid, it is necessary to make the inlet and outlet of the flow path small. For this reason, flow path resistance increases and the load of the fluid drive pump increases.
In addition, since materials with high thermal conductivity are generally hard, it is impossible to deform the flow path from the outside after placing the heat conductor in the flow path, and the shape cannot be changed after the cooling structure is formed. There is also a problem.

  The present invention has been made to solve the above-described problems, and has a light source device having a cooling mechanism with high cooling efficiency and easy shape change, a manufacturing method thereof, and a projection display provided with the light source device. An object is to provide an apparatus.

In order to achieve the above object, a light source device of the present invention is a light source device in which a solid light source is installed on a cooling pipe, and is flexible at a position in the cooling pipe corresponding to the installation position of the solid light source. It is characterized in that the conductive wire is bent and provided in contact with the inner wall of the pipe a plurality of times.
According to this configuration, since the heat of the solid light source can be transmitted to the cooling fluid flowing in the pipe with a large surface area of the wire, the cooling efficiency can be improved as compared with the structure in which the cooling pipe is simply provided. it can. Moreover, since the flow of fluid becomes turbulent by such a wire, the chance of contact of the fluid with the inner wall of the pipe and the wire is increased, and the fluid is agitated so that the whole fluid can contribute to cooling. Furthermore, since the member responsible for heat conduction is made of a flexible wire, for example, when a solid light source is installed on a pipe, a flat portion for installing the light source is easily formed by pressurizing the surface of the pipe. be able to. For this reason, cheap materials, such as a copper pipe, can be used as a cooling pipe.

  As the above-mentioned wire rod, for example, the above-mentioned wire rod is made of a thin wire member, and the thin wire member bent into a cotton shape and disposed in close contact with the inner wall of the pipe can be used. Specifically, glass wool, steel wool (including those made of materials other than stainless steel and iron), and the like can be suitably used. Moreover, as the above-mentioned wire rod, the wire rod may be formed of a tape-shaped member, and the tape-shaped member bent in a wave shape and closely disposed on the inner wall of the pipe may be used.

  The wire is preferably made of a metal material. Of course, it is possible to use an insulating material as a wire material, such as glass wool, but since an insulating material generally has a low thermal conductivity, a metal material having a higher thermal conductivity is used for the wire material to improve the cooling efficiency. Can be increased.

The light source device manufacturing method of the present invention is a light source device manufacturing method in which a solid light source is installed on a cooling pipe, and corresponds to a step of installing a wire in the cooling pipe and an installation position of the wire. A solid light source is installed at a position on the cooling pipe, and the wire is installed by inserting a flexible wire into the cooling pipe and compressing the wire along the extending direction of the pipe. And a step of bending so as to contact the inner wall of the pipe a plurality of times.
According to this method, even if the shape of a pipe is complicated, the said wire can be installed in the desired position in a pipe by retrofit. For this reason, compared with the case where a fin structure is provided on the back surface of the base, for example, manufacturing is easier and cost is advantageous.

In the above method, the step of installing the solid light source includes a step of pressurizing the outer wall portion of the cooling pipe corresponding to the installation position of the wire to form a flat portion on the pipe. In the step of installing the solid light source, You may make it install a solid light source in the flat part of a pipe.
According to this method, even if the cooling pipe has a shape that does not have a flat portion such as a cylindrical shape, the solid light source can be installed thereon. Moreover, when pressurizing the outer wall of the pipe, the wire is compressed by the pipe, whereby the adhesion between the wire and the inner wall of the pipe is increased, and the cooling efficiency can be further improved.

The light source device manufacturing method of the present invention is a light source device manufacturing method in which a solid light source is installed on a cooling pipe, the step of installing the solid light source on the cooling pipe, and the installation position of the solid light source And a step of installing the bent wire at a position in the cooling pipe corresponding to the step of inserting the flexible wire into the cooling pipe and the direction in which the pipe extends. And a step of bending so as to be in close contact with the inner wall of the pipe.
In this method, a solid light source is installed on a cooling pipe, and then a wire is installed in the pipe. This method can provide the same effect as the above method.

The light source device manufacturing method of the present invention is a method of manufacturing a light source device in which a solid light source is installed on a cooling pipe, and the opening is provided inside the cooling pipe having an opening in a part of the outer wall. And a step of inserting a wire bent in a cotton-like manner through the wire and a step of compressing the wire to attach a base on which a solid light source is mounted to the opening. Alternatively, the manufacturing method of the light source device of the present invention is a manufacturing method of a light source device in which a solid light source is installed on a cooling pipe, on a surface opposite to the solid light source of a base on which the solid light source is mounted. A step of fixing the wire bent in a cotton shape and a step of attaching the base to the opening of the cooling pipe having an opening in a part of the outer wall are provided.
In this method, an already bent or cotton-like wire rod such as steel wool is disposed in the pipe through the opening provided in the outer wall of the pipe, and the opening is compressed. Attach the base to For this reason, a wire can be reliably arrange | positioned directly under a solid light source. In addition, this method is easier to manufacture than the case of providing a fin structure on the back surface of the base, for example, and is advantageous in terms of cost.

  According to another aspect of the present invention, there is provided a projection display device comprising: the above-described light source device; a light modulation device that modulates light emitted from the light source device; and a projection lens that projects the modulated light. To do. According to this configuration, bright display is possible by providing the light source device described above.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[First Embodiment]
First, a semiconductor light emitting element (LED) 1 that is an example of a light source device according to a first embodiment of the present invention will be described with reference to FIG. In all the drawings below, the film thicknesses and dimensional ratios of the constituent elements are appropriately changed in order to make the drawings easy to see.

As shown in FIG. 1, the LED 1 of the present embodiment includes a cooling case 31 having a flow path for circulating a cooling fluid and an LED chip 11 as a solid light source installed thereon.
In this embodiment, the bottom surface (surface opposite to the chip 11) of the base 21 on which the chip 11 is mounted is directly cooled by the cooling fluid F. 11 is mounted with an opening 31a for mounting the base 21 mounted thereon. The base 21 is attached so as to cover the opening 31a, and the cooling fluid F flows through the space in the case sealed by the base 21. In addition, the case 31 is provided with an inlet 36 and an outlet 35 for the cooling fluid F on a surface corresponding to a side surface of the surface on which the opening 31 a is formed. The inflow port 36 and the outflow port 35 are connected via a heat radiating portion (not shown), and the cooling fluid F is circulated in the annular flow path. That is, the cooling fluid F is introduced into the cooling case 31 through the inflow port 36, and after the chip 11 is cooled here, it is discharged from the outflow port 35. Then, the discharged cooling fluid F is cooled by the heat radiating portion and is again introduced into the case through the inflow port 36.
In the present embodiment, the cooling case 31 and the members connected to the cooling case 31 and constituting the flow path for circulating the cooling fluid constitute the cooling pipe of the present invention.

The cooling case 31 is packed with stainless fine wires (wires) 25 bent in a cotton shape, and the fine wires 25 are in close contact with the inner wall of the cooling fluid flow path including the bottom surface of the base 21. It is fixed.
For example, when the base 21 is attached to the opening 31a, the thin wire 25 is inserted into the case in a cotton-like state through the opening 31a. And when the base 21 is attached to the opening part 31a, it compresses in the form which is crushed by the bottom face of a base, and is closely_contact | adhered and fixed to the flow-path inner wall. Alternatively, the base 21 may be attached to the opening 35a after the fine wire 25 configured in a cotton shape is fixed to the back surface of the base 21 with solder or the like. The fine wire 25 is preferably subjected to a surface treatment for preventing corrosion as necessary.

  In such a configuration, when the cooling fluid F is caused to flow from the inlet 36 toward the outlet 35 by a pump or the like (not shown), the heat generated from the chip 11 is in a number of points with the base 21 and the base 21. Conducted to the fine wire 25 in contact. Heat is transferred to the cooling fluid F with a large surface area of the thin wire 25.

Therefore, according to this embodiment, compared with the case where there is no thin wire 25, the area which radiates heat to the cooling fluid F is increased, and the cooling efficiency is remarkably increased. In addition, since the turbulent flow is generated when the cooling fluid F passes through the cotton-like thin wire 25, not only the amount of heat transmitted from the thin wire 25 but also the amount of heat directly transmitted from the bottom surface of the base to the cooling fluid F is improved. The cooling efficiency is further increased.
In addition, the present configuration in which the thin wires are arranged in the case in this manner is easy to manufacture and advantageous in terms of cost as compared with, for example, a fin structure provided on the back surface of the base.

[Second Embodiment]
Next, a light source device according to a second embodiment of the present invention will be described with reference to FIG. In the present embodiment, the same members or parts as those in the first embodiment are denoted by the same reference numerals, and the description thereof is partially omitted.
In the present embodiment, a cylindrical copper pipe is used as a cooling pipe for circulating a cooling fluid. That is, the LED (light source device) 2 of the present embodiment includes a copper pipe 32 having a flow path for cooling fluid circulation, and an LED chip 11 as a solid light source installed thereon.

  The pipe 32 is partially flattened by a press or the like, and the base 22 on which the chip 11 is mounted is installed on the flat portion 37. The pipe is filled with a copper thin wire (wire) 26 bent in a cotton shape, and the thin wire 26 is fixed at a position corresponding to the installation position of the chip 11 in close contact with the inner wall of the pipe. Has been.

The thin wire 26 is disposed in the pipe as follows, for example.
First, the copper thin wire 26 is inserted linearly (that is, not bent into a cotton shape) from one end of the pipe, and pressed and compressed from both sides of the pipe with a rod-shaped piston slightly smaller than the inner diameter of the pipe. . As a result, the thin wire 26 is bent and deformed into a cotton shape, and is fixed in a state of being in close contact with the inner wall (that is, the inner wall of the flow path) of the pipe.
Next, the outer wall portion of the pipe 32 corresponding to the installation position of the thin wire 26 is pressurized from the outside by a press or the like to form a flat portion 37 on the outer periphery of the pipe. As a result, the thin wire 26 is crushed in a direction perpendicular to the flow path, and the adhesion to the inner wall of the pipe is further increased.
Then, the base 22 on which the chip 11 is mounted is installed on the flat portion 37.

  As described above, also in this embodiment, a light source device with high cooling efficiency and capable of bright illumination can be configured. In addition, as in this embodiment, if a method of inserting the thin wire 26 into the pipe as it is and compressing and bending it from both sides is used, the thin wire is retrofitted regardless of the type and shape of the pipe. It can arrange | position reliably in the desired position. For this reason, for example, the manufacturing becomes easier and the cost is advantageous as compared with the case where the fin structure is provided in the flow path. Furthermore, since the member responsible for heat conduction (thin wire 26) is made of a flexible wire, compared to the structure of Patent Document 3 in which this is a granular member, deformation of the flow path from the outside (in this embodiment, chip placement) Pressure treatment for forming a flat portion for use is facilitated. For this reason, the kind and shape of the pipe can be arbitrarily determined, and for example, an inexpensive material such as a copper pipe can be used as the cooling pipe.

  In the present embodiment, the fine wire 26 is stuffed into the pipe in a cotton shape, and then the pipe 32 is pressurized to form the flat portion 37. Either the step of installing the thin wire in the pipe or the step of installing the chip on the pipe may be performed first. For example, after a chip is installed on the cooling pipe, it is also possible to pack the fine wire by bending it into a cotton shape at a position in the cooling pipe corresponding to the installation position of the chip. In this case, in the thin wire installation process, as in the above-described process of the present embodiment, first, the flexible wire is inserted into the pipe in a linear form from the side of the pipe, and then the wire is inserted into the pipe. It can be performed by compressing along the extending direction and bending it so as to be in close contact with the inner wall of the pipe.

[Projection type display device]
Next, the projection type display device of the present invention will be described with reference to FIG.
The projection display device according to the present embodiment is a three-plate projection color liquid crystal display device having a transmissive liquid crystal light valve for each color of R (red), G (green), and B (blue). FIG. 3 is a schematic configuration diagram showing this projection type liquid crystal display device. In the figure, reference numerals 100R, 100G, and 100B denote illumination devices, 111 and 112 denote fly-eye lenses, and 200R, 200G, and 200B denote liquid crystal light valves (light Modulator), 300 is a cross dichroic prism (color synthesis means), and 400 is a projection lens.

  Light valves 200R, 200G, and 200B as light modulators are arranged to face each other on the three light incident surfaces of the dichroic cross prism 300 as the color synthesizing means, and the back side of each light valve (with the cross dichroic prism 300 and On the opposite side, illumination devices 100R, 100G, and 100B capable of emitting color lights of R (red), G (green), and B (blue) are arranged. These illumination devices are formed by juxtaposing a plurality of the light source devices described above.

  Between the lighting devices 100R, 100G, and 100B and the corresponding light valves 200R, 200G, and 200B, as the illuminance uniformizing means 110 for uniformizing the illuminance distribution of the illumination light on the light valve, the lighting device side To the first fly-eye lens 111 and the second fly-eye lens 112 are sequentially installed. The first fly-eye lens 111 forms a plurality of secondary light source images, and the second fly-eye lens 112 functions as a superimposing lens that superimposes them at the light valve installation position, which is the illuminated area. Thereby, the light emitted from the illumination device can be irradiated to the entire surface of the light valve at a uniform density regardless of the density distribution of the light.

The dichroic cross prism 300 has a structure in which four right-angle prisms are bonded together, and light reflection films (not shown) made of a dielectric multilayer film are formed in a cross shape on the bonded surfaces 300a and 300b. Specifically, the reflection surface that reflects the red image light formed by the light modulation device 200R and transmits the green and blue image light formed by the light modulation devices 200G and 200B to the bonding surface 300a, respectively. A light reflection that reflects the blue image light formed by the light modulation device 200B and transmits the red and green image light formed by the light modulation devices 200R and 200G, respectively, is provided on the bonding surface 300b. A membrane is provided. The image light of each color guided by these light reflecting films is projected onto the screen 500 by the projection lens 400.
Thus, since the projection type display apparatus of this embodiment is equipped with the above-mentioned light source device as an illuminating device, a bright display is attained.

In addition, this invention is not limited to the above-mentioned embodiment, It can implement in various deformation | transformation in the range which does not deviate from the meaning of this invention.
For example, in the above embodiment, a thin wire-like member bent into a cotton shape is used as the wire, but instead, a tape-like member is used as the wire, and this is bent into a wave shape to form the inner wall of the cooling pipe. You may arrange closely.

Moreover, although stainless steel and copper were used as a raw material of a wire, you may use metal materials other than this. Of course, it is possible to use an insulating material as a wire material, such as glass wool, but since an insulating material generally has a low thermal conductivity, a metal material having a higher thermal conductivity is used for the wire material, thereby improving the cooling efficiency. Can be increased.
Moreover, although the shape of the wire was made into cotton in the said embodiment, other shapes, such as a coil shape, can also be taken. In any case, it is sufficient that the flexible wire is bent and provided in contact with the inner wall of the pipe a plurality of times.
Moreover, although the cooling fluid is used as the fluid for cooling the solid light source, it is also possible to use a gas such as an inert gas as such a fluid.

Moreover, although the said embodiment demonstrated the example which used the light source device as the semiconductor light emitting element, this light source device may be an organic EL element. In addition, the configuration of the light source device shown in the above embodiment is merely an example, and other configurations can be employed.
In addition, the cooling mechanism of the present invention in which a flexible wire is bent in the cooling pipe can be applied to cooling other electronic components that generate heat in addition to the cooling of the solid light source. In this case, the cooling mechanism may be provided by providing a flexible wire in the cooling pipe and bending the wire so as to contact the inner wall of the cooling pipe a plurality of times. In addition, this structure can be applied not only to the heat absorbing portion but also to a heat radiating portion such as a heat sink.

1 is a cross-sectional view illustrating a schematic configuration of a light source device according to a first embodiment of the present invention. Sectional drawing which shows schematic structure of the light source device which concerns on 2nd Embodiment of this invention. The figure which shows schematic structure of the projection type display apparatus of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1, 2 ... LED (light source device), 11 ... LED chip (solid light source), 21, 22 ... Base, 25, 26 ... Wire rod, 31, 32 ... Cooling pipe, 31a ... Opening Part, 37... Flat part, 100R, 100G, 100B ... illumination device, 200R, 200G, 200B ... liquid crystal light valve (light modulation device), 400 ... projection lens, F ... cooling fluid

Claims (10)

A light source device in which a solid light source is installed on a cooling pipe,
A light source device, wherein a flexible wire is bent at a position in a cooling pipe corresponding to an installation position of a solid light source so as to be in contact with the inner wall of the pipe a plurality of times.   The light source device according to claim 1, wherein the wire is made of a thin wire member, and the thin wire member is bent into a cotton shape and closely attached to the inner wall of the pipe.   The light source device according to claim 1, wherein the wire is made of a tape-like member, and the tape-like member is bent in a wave shape and is closely attached to the inner wall of the pipe.   The light source device according to claim 1, wherein the wire is made of a metal material. A method of manufacturing a light source device in which a solid light source is installed on a cooling pipe,
Installing a wire in the cooling pipe;
A step of installing a solid light source at a position on the cooling pipe corresponding to the installation position of the wire,
The step of installing the wire includes a step of inserting a flexible wire into the cooling pipe, compressing the wire along the extending direction of the pipe, and bending the wire so as to contact the inner wall of the pipe a plurality of times. A method for manufacturing a light source device. The installation step of the solid light source includes a step of pressurizing the outer wall portion of the cooling pipe corresponding to the installation position of the wire to form a flat portion on the pipe,
6. The method of manufacturing a light source device according to claim 5, wherein in the step of installing the solid light source, the solid light source is installed on a flat portion of the pipe. A method of manufacturing a light source device in which a solid light source is installed on a cooling pipe,
Installing a solid light source on the cooling pipe;
And a step of installing a wire at a position in the cooling pipe corresponding to the installation position of the solid-state light source,
The step of installing the wire includes a step of inserting a flexible wire into the cooling pipe, compressing the wire along the extending direction of the pipe, and bending the wire so as to contact the inner wall of the pipe a plurality of times. A method for manufacturing a light source device. A method of manufacturing a light source device in which a solid light source is installed on a cooling pipe,
Inserting a wire bent in a cotton shape through the opening into the inside of the cooling pipe having an opening in a part of the outer wall;
And a step of attaching a base on which a solid-state light source is mounted to the opening in a form of compressing the wire. A method of manufacturing a light source device in which a solid light source is installed on a cooling pipe,
Fixing a cotton-like bent wire on the surface of the base on which the solid light source is mounted opposite to the solid light source;
And a step of attaching the base to the opening of the cooling pipe having an opening in a part of the outer wall. A light source device according to any one of claims 1 to 4, a light modulation device that modulates light emitted from the light source device, and a projection lens that projects the modulated light. Projection type display device.

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