Light-cured 3D printer, optical system thereof and operating method thereof

Abstract

The application belongs to the technical field of 3D printing, and provides a light-curing 3D printer, an optical system thereof and an operating method. The optical system comprises: a plurality of light-emitting assemblies, each of which comprises one or more LEDs emitting ultraviolet light; and a controller comprising a plurality of channels, each of which is used for providing a driving current, and the controller is configured to independently control each of the light-emitting assemblies; wherein the LEDs of the light-emitting assemblies are configured to: be electrically connected to at least two of the channels and connected to a first driving voltage; be electrically connected to a current amplification circuit, the current amplification circuit being electrically connected to the channels of the controller and connected to a second driving voltage; or comprise a plurality of sub-LED wafers that are cut, the plurality of sub-LED wafers being connected in series and electrically connected to the channels of the controller and connected to a third driving voltage. The embodiments of the application can independently control a single LED, and improve controllability and flexibility of a light source.

Description

Technical Field

[0001] This application belongs to the field of 3D printing technology, and in particular relates to a photopolymerization 3D printer, its optical system, and its operating method. Background Technology

[0002] With the continuous development of 3D printing technology, various types of 3D printing equipment are gradually being widely used in people's lives. For example, photopolymerization 3D printers based on Digital Light Processing (DLP) technology or Liquid Crystal Display (LCD) technology, such as LCD printers, usually adopt an integrated light source design (e.g., LCD printers use COB (Chip on Board) light sources), which cannot independently control individual light-emitting diodes (LEDs), resulting in poor controllability and flexibility of the light source.

[0003] In display fields such as TVs, zone-controlled LED arrays have emerged. However, LED arrays used in TVs cannot be directly reused in the 3D printing field. LED arrays used in TVs typically use LEDs that emit white light; however, photopolymer 3D printing typically uses ultraviolet light, and the intensity of the ultraviolet light needs to be sufficient to cure the resin within a predetermined time (e.g., 2 seconds).

[0004] Therefore, there is a need to provide LED arrays suitable for photopolymer 3D printing. Summary of the Invention

[0005] In view of this, embodiments of this application provide a photopolymerization 3D printer, its optical system, and operating method, which enables independent control of individual LEDs, improving the controllability and flexibility of the light source.

[0006] A first aspect of this application provides an optical system for a photopolymerization 3D printer, comprising:

[0007] Multiple light-emitting components, each comprising one or more LEDs emitting ultraviolet light; and

[0008] A controller comprising multiple channels, each channel being configured to provide a drive current, the controller being configured to independently control each of the light-emitting components;

[0009] The LEDs of the light-emitting component are configured as follows:

[0010] At least two of the channels are electrically connected and a first driving voltage is applied.

[0011] An electrical connection is made to a current amplification circuit, which is electrically connected to a channel of the controller and connected to a second driving voltage; or

[0012] It includes multiple sub-LED wafers that have been cut and connected in series, and are electrically connected to the channel of the controller and connected to a third driving voltage.

[0013] In some embodiments, the current amplification circuit includes a first resistor unit, a second resistor unit, and a transistor unit;

[0014] The first end of the first resistor unit is electrically connected to the input terminal of the transistor unit and is connected to the second driving voltage; the second end of the first resistor unit is electrically connected to the first end of the second resistor unit and is connected to the driving current.

[0015] The second terminal of the second resistor unit is electrically connected to the controlled terminal of the transistor unit;

[0016] The output terminal of the transistor unit is electrically connected to an LED.

[0017] In some embodiments, the third driving voltage is greater than the first driving voltage and the second driving voltage.

[0018] In some embodiments, the optical system further includes a power supply circuit, which includes a plurality of step-down circuits, each step-down circuit being used to convert the input power supply voltage into a driving voltage, wherein the driving voltage is the first driving voltage, the second driving voltage, or the third driving voltage.

[0019] In some embodiments, the step-down circuit includes a DC-DC step-down circuit and a voltage regulation circuit.

[0020] In some embodiments, the optical system further includes a processor, wherein when the driving voltage associated with the channel is lower than a first preset voltage, the controller outputs a low-voltage warning signal to the processor, and the processor is configured to increase the driving voltage of the LED associated with the channel based on the low-voltage warning signal; and / or

[0021] When the driving voltage associated with the channel is higher than a second preset voltage, the controller outputs a high-voltage warning signal to the processor, which is configured to reduce the driving voltage of the LED associated with the channel based on the high-voltage warning signal.

[0022] In some embodiments, the controller is configured to:

[0023] When a short circuit is determined in the channel based on the drive current voltage of the channel, a short circuit signal is output; and / or

[0024] When it is determined that the channel is open-circuited based on the drive current of the channel, an open-circuit signal is output.

[0025] In some embodiments, the controller is configured to adjust the current or PWM of the light-emitting component.

[0026] In some embodiments, the plurality of ultraviolet-emitting LEDs include:

[0027] A first LED and a second LED, wherein the emission wavelength of the first LED is different from that of the second LED; or

[0028] The first LED and the second LED have the same emission wavelength.

[0029] A second aspect of this application provides a photopolymerization 3D printer, comprising:

[0030] A molding platform configured to adhere at least one cured layer;

[0031] A support device configured to support printing material;

[0032] A drive assembly configured to drive the molding platform to move closer to or away from the support device; and

[0033] A first aspect of the optical system, wherein the ultraviolet light emitted by the optical system is configured to cure the printing material to form the cured layer.

[0034] A third aspect of this application provides an operation method for a photopolymerization 3D printer as described in the second aspect, comprising:

[0035] The optical system emits light using a first plurality of light-emitting components, projecting ultraviolet light onto the printing material in the carrier device to form a first cured layer with a first contour; then

[0036] The optical system uses a second plurality of light-emitting components to emit light, projecting ultraviolet light onto the printing material in the carrier device to form a second cured layer with a second contour.

[0037] The first plurality of light-emitting components are different from the second plurality of light-emitting components.

[0038] The optical system of the photopolymer 3D printer provided in the first aspect of this application can improve the controllability and flexibility of the light source. By configuring each LED to be electrically connected to at least two channels of the controller, the high driving current required for a single LED when it is independently controlled can be provided by merging the driving current of at least two channels. By electrically connecting each LED to a current amplification circuit and electrically connecting each current amplification circuit to a channel, the driving current can be amplified by the current amplification circuit to provide the high driving current required for a single LED when it is independently controlled. By cutting each LED into multiple sub-LED wafers connected in series, the driving current required for a single LED is reduced and the driving voltage required for a single LED is increased while the luminous power of a single LED remains unchanged. By electrically connecting multiple sub-LED wafers connected in series to a channel and connecting them to a high driving voltage, the driving current required for a single LED and the high driving voltage required for multiple sub-LED wafers connected in series can be provided when the single LED is independently controlled without increasing the driving current of a single channel. Each LED in the optical system can be configured in any of the above ways. Different LEDs can use different configurations, meaning that multiple different configurations can coexist in the optical system. The configuration can be selected based on actual needs such as cost, process complexity, and size, offering high flexibility.

[0039] It is understandable that the beneficial effects of the second aspect mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 This is one of the optical path schematic diagrams of the optical system provided in the embodiments of this application;

[0042] Figure 2A-2B This is a schematic diagram of the energy distribution of the light spot formed by the light emitted from the optical component provided in some embodiments of this application after passing through the collimating component;

[0043] Figure 3 The energy distribution curves of light emitted from multiple optical components in the embodiments of this application before and after fusion on the target plane are shown.

[0044] Figure 4 This is a schematic diagram of the optical path of an optical system provided in some embodiments of this application;

[0045] Figure 5 This is a schematic diagram of the optical path of an optical system provided in some other embodiments of this application;

[0046] Figures 6A-6B This is a light intensity distribution diagram of the light emitted by the optical component provided in this application embodiment before and after passing through the diffuser;

[0047] Figures 7A-7B The light intensity distribution curves of multiple light spots combined are provided in some embodiments of this application;

[0048] Figures 8A-8C A schematic diagram of an optical system with a mask provided in some embodiments of this application;

[0049] Figures 9A-9D A schematic diagram of an optical system with a mask provided for some embodiments of this application;

[0050] Figures 10A-10F This is a schematic diagram illustrating the arrangement of light-emitting components or collimating lenses provided in some embodiments of this application;

[0051] Figure 11 A schematic diagram of the optical path of an optical system with a light-shielding element provided in an embodiment of this application;

[0052] Figures 12A-12E This is a schematic diagram of the structure of the optical module provided in the embodiments of this application;

[0053] Figure 13 This is a schematic diagram of the structure of the light-shielding element provided in the embodiments of this application;

[0054] Figure 14 A photopolymer 3D printing apparatus according to some embodiments is shown;

[0055] Figure 15 A photopolymer 3D printing apparatus according to some embodiments is shown;

[0056] Figure 16 This is a circuit diagram of the optical system provided in an embodiment of this application;

[0057] Figure 17 This is a circuit diagram of the optical system provided in an embodiment of this application;

[0058] Figure 18 This is a circuit diagram of the optical system provided in an embodiment of this application;

[0059] Figure 19 This is a circuit diagram of the optical system provided in an embodiment of this application;

[0060] Figure 20This is a circuit diagram of the optical system provided in an embodiment of this application;

[0061] Figure 21 This is a circuit diagram of the optical system provided in an embodiment of this application;

[0062] Figure 22 This is a circuit diagram of the current amplification circuit provided in the embodiments of this application;

[0063] Figure 23 This is a circuit diagram of the current amplification circuit provided in the embodiments of this application;

[0064] Figure 24 This is a circuit diagram of the power supply circuit in the optical system provided in the embodiments of this application;

[0065] Figure 25 This is a circuit diagram of the DC-DC buck circuit provided in the embodiments of this application;

[0066] Figure 26 This is a circuit diagram of the optical system provided in an embodiment of this application;

[0067] Figure 27 This is a circuit diagram of the optical system provided in an embodiment of this application;

[0068] Figure 28 This is a circuit diagram of the optical system provided in an embodiment of this application. Detailed Implementation

[0069] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0070] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0071] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized. "A plurality" means "two" or "more than two."

[0072] Please see Figure 1 The optical system provided in this application includes a light-emitting component 101, a collimating component 102, and a controller. The light-emitting component 101 is configured to emit light. There are multiple light-emitting components 101 and collimating components 102, with each light-emitting component 101 having one collimating component 102. The collimating component 102 is used to collimate the light emitted by the corresponding light-emitting component 101. The controller is electrically connected to each light-emitting component 101 and can individually control the activation or deactivation of each light-emitting component 101, or control the light emission intensity of each light-emitting component 101.

[0073] Light from the light-emitting component 101 passes through the collimating component 102 and illuminates the target plane 104 to form an illumination area. The illumination areas of two adjacent light-emitting components 101 at least partially overlap to form an overlapping area. The light intensity of the overlapping area is 80% to 120% of the light intensity of the non-overlapping area of ​​the illumination area, preferably 85% to 115%, preferably 90% to 110%, preferably 95% to 105%, for example 96%, 97%, 98%, 99%, 100%, 101%, 102%, 103%, 104%, and 105%.

[0074] Each light-emitting component 101 forms a light spot on the target plane 104, which is divided into a central region S201 and an edge region S202. The light intensity of the central region S201 is greater than that of the edge region S202. The light intensity of the central region S201 is basically uniform, while the light intensity of the edge region S202 gradually decreases away from the central region. Taking the formation of a quadrilateral light spot on the target plane 104 by a single light-emitting component 101 as an example, see [reference needed]. Figure 2A The light intensity of the light spot is relatively strong and uniform in the central region S201, and gradually decreases to zero in the edge region S202 along the direction away from the central region. The light intensity distribution is roughly in the shape of an isosceles trapezoid.

[0075] In related designs, the combined light spot formed by multiple light-emitting components 101 is prone to bright or dark spots, resulting in uneven light distribution. (See also...) Figure 2B The light spots formed by two adjacent light-emitting components 101 on the target plane 104 have an overlapping region S210, which is formed, for example, by the overlapping of the edge regions S202 of the two light spots.

[0076] To avoid bright or dark spots, the light intensity of the edge region S202 is enhanced by overlapping, making it essentially the same as the light intensity of the central region S201. In one example, after one light-emitting component 101 emits light, other light-emitting components 101 adjacent to it are controlled to emit light, so that the light intensity of the edge region of the light spot of the light-emitting component 101 on the target plane is increased due to the adjacent light-emitting components 101, thereby making the light intensity of the overlapping region S210 of the light spot essentially the same as the light intensity of the central region S201.

[0077] In one example, a first light-emitting component 101 forms a first illumination area on a target plane 104, and a second light-emitting component 101 adjacent to the first light-emitting component 101 forms a second illumination area on the target plane 104. The first and second illumination areas form an overlapping area on the target plane 104. The light intensity of the overlapping area is the sum of the light intensity of the first light-emitting component illuminating the overlapping area and the light intensity of the second light-emitting component illuminating the overlapping area. The light intensity of the non-overlapping area in the first illumination area is the light intensity of the first light-emitting component illuminating the central area of ​​the first illumination area. The light intensity of the non-overlapping area in the second illumination area is the light intensity of the second light-emitting component illuminating the central area of ​​the second illumination area.

[0078] In one example, the light intensity of the non-overlapping area in the first illumination region is the same as that of the non-overlapping area in the second illumination region. The light intensity of the overlapping area is 80%–120% of the light intensity of the non-overlapping area in the first illumination region and also 80%–120% of the light intensity of the non-overlapping area in the second illumination region. Thus, the first and second illumination regions merge to form a uniform light spot. For example, the light intensity (light power density) of the non-overlapping area in the first illumination region is 30 mW / cm². 2 The luminous intensity in the non-overlapping area of ​​the second lighting region is 30 mW / cm². 2 The luminous intensity of the overlapping area of ​​the first or second illumination area is 28 mW / cm². 2 29mW / cm 2 30mW / cm 2 31mW / cm 2 32mW / cm 2 .

[0079] In one example, the light intensity of the non-overlapping area in the first illumination region is different from that of the non-overlapping area in the second illumination region. The light intensity of the overlapping area is 80%–120% of the light intensity of the non-overlapping area in both the first and second illumination regions. This causes the first and second illumination regions to merge and form a uniform light spot. For example, the light intensity of the non-overlapping area in the first illumination region is 30 mW / cm². 2 The luminous intensity in the non-overlapping area of ​​the second illumination region is 35 mW / cm². 2 The luminous intensity of the overlapping area of ​​the first or second illumination area is 30 mW / cm². 2 31mW / cm 2 32mW / cm 2 33mW / cm 2 35mW / cm 2 .

[0080] The light emitted by the light-emitting component 101 is ultraviolet or visible light of a specific wavelength and energy, which can act on the printing material to achieve a curing effect. In one embodiment, each light-emitting component 101 has only one LED. In another embodiment, the light-emitting component 101 includes two, three, or more LEDs. When the light-emitting component 101 includes multiple LEDs, the light emitted by the multiple LEDs in the same light-emitting component 101 can be of the same or different wavelengths. The structures of the multiple light-emitting components 101 can be the same or different. For example, some of the multiple light-emitting components 101 include only one LED, while some of the multiple light-emitting components 101 include multiple LEDs. Alternatively, each light-emitting component 101 includes multiple LEDs.

[0081] In this article, "LED" includes various types of LEDs, such as Mini LEDs and Micro LEDs. The chip size of the LEDs in this article is, for example, 20μm to 500μm, 40μm to 400μm, or 50μm to 200μm.

[0082] In some embodiments, the target plane 104 is an LCD screen.

[0083] In some embodiments, the target plane 104 is a film containing a tray of printing material.

[0084] In some embodiments, the target plane 104 is a mask.

[0085] In some embodiments, the target plane 104 is the plane between the light-emitting component and the LCD screen.

[0086] In some embodiments, the target plane 104 is the liquid surface of the printing material contained in the tray. For example, the light emitted by the light-emitting component 101 directly or indirectly radiates the liquid surface (upper surface) of the printing material.

[0087] Based on the pattern of the slice layer to be cured of the object, the controller controls at least one of all light-emitting components 101 to emit light. All light-emitting components of the optical system are controlled independently; for example, the controller can control 10, 20, or 50 light-emitting components 101 to emit light simultaneously, rather than having to turn all light-emitting components on or off at the same time.

[0088] In some embodiments, the mounting spacing between two adjacent light-emitting components is designed such that the light intensity of the overlapping region of the light spots of the two adjacent light-emitting components on the target plane is 80% to 120% of the light intensity of the non-overlapping region. For example, the light intensity of the overlapping region is 90%, 100%, or 110% of the light intensity of the non-overlapping region in the first region.

[0089] The optical system provided in this application features multiple light-emitting components 101 independently controlled by a controller. During printing, the controller controls one or more corresponding light-emitting components 101 to emit light, saving energy compared to existing systems where all light-emitting components are either fully on or fully off. Furthermore, in 3D printers with LCD screens, the LCD screen, acting as a mask, may allow unwanted light to pass through (e.g., when the grayscale is set to 0). Although the intensity of the transmitted light is reduced, this is still disadvantageous. In the optical system of this application, some light-emitting components 101 emit light during operation, while the remaining light-emitting components 101 do not emit light, effectively preventing unwanted light from passing through the mask or LCD screen and improving contrast.

[0090] The mounting plate has 100 to 15,000 light-emitting components 101. For example, 1,000 light-emitting components 101 are mounted on the mounting plate. The overlap area of ​​two adjacent light-emitting components 101 on the target plane 104 is related to the mounting dimensions of the two light-emitting components 101.

[0091] For a given model of photopolymer 3D printing equipment, the area available for exposure is limited by the equipment size, thus limiting the area of ​​the mounting plate (on which multiple light-emitting components are mounted). Those skilled in the art will understand that a larger number of light-emitting components 101, such as 2000, or a smaller number, such as 180, can be mounted on the same mounting plate area. Different numbers of light-emitting components 101 are suitable for different mounting dimensions (e.g., mounting spacing) and structural designs. Furthermore, different numbers of light-emitting components 101 are suitable for different types (e.g., different sizes) of LEDs.

[0092] In some embodiments, a plurality of (e.g., 200) light-emitting components 101 are mounted on the mounting plate, and the arrangement of these light-emitting components 101 allows the light spots of two adjacent light-emitting components 101 to have overlapping areas on the target plane 104, for example, overlapping only in the edge area of ​​the light spots.

[0093] In some embodiments, a plurality (e.g., 1000) of light-emitting components 101 are mounted on the mounting plate, and these light-emitting components 101 are compact. Due to this compact arrangement and the propagation distance of the light emitted by the light-emitting components, the optical distance between adjacent light-emitting components 101 is unavoidable. In other words, the light spots of two adjacent light-emitting components 101 on the target plane 104 have overlapping areas, for example, a portion of the central region and the edge region of the light spot overlap, which makes the light intensity of at least a portion of the overlapping region always undesirably greater than the light intensity of the non-overlapping region. To at least avoid this drawback, this application ensures that the area / length of the overlapping region between two adjacent light spots occupies half the area / length of a single light spot (e.g., refer to...). Figure 4 This will be discussed in detail later.

[0094] In some embodiments, the light emitted by each light-emitting component, after passing through the collimating component, forms a light spot with an intensity that is approximately arranged in an isosceles trapezoidal shape. (See reference...) Figure 3 The light intensity of the light spot formed by the fusion of the light emitted by the three light-emitting components on the target plane is higher in the overlapping region than in the non-overlapping region. In some embodiments, the light intensity in the overlapping region may also be lower than that in the non-overlapping region.

[0095] See Figure 4 The optical system includes a light-emitting component 401, a collimating component 402, and a compound eye array (or diffuser) 403. The compound eye array 403 is disposed on the side of the collimating component 402 away from the light-emitting component 401, and is used to diffuse the light passing through the collimating component 402. The light passing through the compound eye array 403 forms multiple light spots on the target plane 404, with adjacent light spots having overlapping areas.

[0096] See Figure 6A The left-side image of the light spot, for example, shows a hexagonal light spot formed by light emitted from a single light-emitting component 401 before entering the compound eye array 403 after passing through the collimating component 402. The light intensity is stronger in the central region of the light spot and weaker in the edge region. (See also...) Figure 6A The right-side side light spot image, for example, the light emitted by a single light-emitting component 401 passes through the collimating component 402 and the compound eye array 403 in sequence and then diffuses to the surroundings, maintaining the original light intensity. The area of ​​the central region shrinks, the area of ​​the edge region expands, and the total area of ​​the light spot expands.

[0097] Taking the formation of a regular hexagonal light spot on the target plane by the light from each light-emitting component 401 as an example, see [reference]. Figure 6B In the left-side illumination area, the light spot of multiple light-emitting components 401 before entering the compound eye array 403 is composed of multiple regular hexagons. At this time, there is a significant difference in light intensity between the overlapping area (the edge area of ​​the regular hexagon) and the non-overlapping area (the center area of ​​the regular hexagon), resulting in bright spots during printing. (See also...) Figure 6B In the right-side illumination area, the light intensity of most areas (central area) of the combined light spot formed on the target plane 404 by the light emitted by multiple light-emitting components 401 after being adjusted by the compound eye array 403 is basically the same.

[0098] Reference Figure 4 and Figure 6A Therefore, when multiple light-emitting components 401 emit light, the light emitted by each light-emitting component 401, after being adjusted by the collimating component 402 and the compound eye array 403, will diffuse more into the illumination area of ​​adjacent light-emitting components 401. Simultaneously, the light emitted by adjacent light-emitting components 401 will also diffuse more into the illumination area of ​​that light-emitting component 401. This increases the size of the overlapping area, achieving a uniform distribution of light energy through the superposition of light from multiple adjacent light-emitting components 401. The central axis distance between two adjacent light-emitting components 401 is d. The light emitted by each light-emitting component 401 passes through the corresponding collimating component 402 and is diffused by the compound eye array 403, forming a light spot with a diameter of D on the target plane 404. Where D > d.

[0099] In some embodiments, the central axis of the light-emitting component 401 refers to the geometric center of the LED.

[0100] exist Figure 4 In the illustrated embodiment, three light-emitting components 401 are arranged along a predetermined direction such that the light emitted from the middle light-emitting component 401 approaches or reaches the central axis of the two side light-emitting components 401 after passing through the collimating component 402 and the compound eye array 403. Similarly, the light emitted from each of the two side light-emitting components 401 approaches or reaches the central axis of the middle light-emitting component 401 after passing through the collimating component 402 and the compound eye array 403. Those skilled in the art will understand that, along the predetermined direction of the arrangement of the light-emitting components 401, the length of the overlapping region between the light spot formed by the middle light-emitting component 401 and the light spot formed by the adjacent single light-emitting component 401 is equal to the length of the non-overlapping region. In other words, along the predetermined direction of the arrangement of the light-emitting components 401, the length of the overlapping region between the light spot formed by the middle light-emitting component 401 and the light spot formed by the adjacent single light-emitting component 401 is equal to half the length of the light spot. Figure 4 As shown, D = 2d, and the light intensity of the overlapping area of ​​the light spots is determined by the two light-emitting components 401.

[0101] exist Figure 5 In the illustrated embodiment, eight light-emitting components 411 are arranged along a predetermined direction such that the light emitted by the third light-emitting component 411 approaches or reaches the central axis of the first and fifth light-emitting components 411 after passing through the collimating component 412 and the compound eye array 413. Similarly, the light emitted by the fourth light-emitting component 411 approaches or reaches the central axis of the second and sixth light-emitting components 411 after passing through the collimating component 412 and the compound eye array 413. Similarly, the light emitted by the fifth light-emitting component 411 eventually approaches or reaches the central axis of the third and seventh light-emitting components 411. The light emitted by the sixth light-emitting component 411 eventually approaches or reaches the central axis of the fourth and eighth light-emitting components 411. Those skilled in the art will understand that, along the predetermined direction of the arrangement of the light-emitting components, the length of the overlap area between the light spot formed by the middle light-emitting component and the light spots formed by adjacent individual light-emitting components is equal to one-quarter of the length of the light spot. Figure 5 As shown, D = 4d, and the light intensity of the overlapping area of ​​the light spots is determined by the four light-emitting components.

[0102] Similarly, D = 2 * d * n. Where D is the length / diameter of the light spot formed after collimation and diffusion of light emitted by a single light-emitting component; d is the distance between the central axes of two adjacent light-emitting components; and n is an integer, such as 1, 2, 3, 4.

[0103] exist Figure 4 and Figure 5 In the illustrated embodiment, a first light-emitting component and a second light-emitting component adjacent to the first light-emitting component along a predetermined direction are arranged. The illumination areas of the first light-emitting component and the second light-emitting component partially overlap and have an overlapping area.

[0104] exist Figure 4 In the aforementioned predetermined direction, the length of the overlapping area is half the length of the illumination area of ​​the first or second light-emitting component. Due to the presence of a diffuser, when only the first and second light-emitting components are activated, the total light intensity of the overlapping area is 80% to 120% of the light intensity of the non-overlapping area of ​​the illumination area of ​​the first or second light-emitting component.

[0105] exist Figure 5 In the aforementioned predetermined direction, the length of the overlapping area is three-quarters of the length of the illumination area of ​​the first or second light-emitting component. Due to the presence of a diffuser, the light spot size increases, and the uniformity of light intensity of a single light spot decreases. When only the first and second light-emitting components are activated, the total light intensity of the overlapping area is, for example, 180% to 300% of the light intensity of the non-overlapping area of ​​the illumination area of ​​the first or second light-emitting component. When eight adjacent light-emitting components are activated along the predetermined direction, the light intensity of the overlapping area simultaneously affected by four light-emitting components is substantially uniform.

[0106] For example, the luminous intensity of the non-overlapping region of the illumination area of ​​the first light-emitting component is 30 mW / cm². 2 The luminous intensity of the overlapping region of the illumination area of ​​the first light-emitting component (i.e., the overlapping region of the illumination area of ​​the second light-emitting component) is 60 mW / cm². 2 The luminous intensity of the non-overlapping region of the illumination area of ​​the second light-emitting component is 30 mW / cm². 2 .

[0107] It is understood that if three or more adjacent light-emitting components are activated simultaneously along a predetermined direction, the entire illumination area of ​​one or more of these components will partially overlap with the illumination areas of the other components. For example, the illumination area of ​​one component may simultaneously overlap with the illumination areas of two adjacent components (see...). Figure 4 ), or the illumination area of ​​one light-emitting component overlaps with three adjacent illumination areas simultaneously (see Figure 5 ).

[0108] See Figure 7A The light emitted by the light-emitting component 401, after passing through the collimating component 402 and the compound eye array 403, exhibits a parabolic intensity distribution in the resulting light spot (i.e., high intensity in the center and low intensity at the edges). The light emitted by the three light-emitting components 401 sequentially passes through the collimating component 402 and the compound eye array 403 before merging on the target plane 404, resulting in a roughly isosceles trapezoidal light spot. In other words, the light intensity is uniform across most of the area illuminated by the light-emitting components. (See also...) Figure 7B The light emitted by a single light-emitting component 401 has a larger spot size after passing through the collimating component 402 and the compound eye array 403, and the light emitted by the three light-emitting components 401 merges on the target plane 404 after sequentially passing through the collimating component 402 and the compound eye array 403. Figure 7A different, Figure 7B The area illuminated by the light-emitting components is affected by a maximum of three light-emitting components, while Figure 7A The area illuminated by the light-emitting components is affected by a maximum of two light-emitting components.

[0109] Combination Figure 4-5 and Figures 7A-7B Adjusting the distance between the compound eye array 403 and the target plane 404 can control the size and intensity of the light spot formed on the target plane 404.

[0110] For some implementations where installation dimensions are limited. Figure 4-5 The proposed solution is advantageous because it makes full use of the coverage of overlapping areas to achieve uniform light intensity, rather than avoiding overlapping areas.

[0111] In one embodiment of this application, only one of the back and front faces of each cell in the compound eye array 403 is convex. In another embodiment of this application, both the back and front faces of each cell in the compound eye array 403 are convex.

[0112] In one embodiment of this application, the cells of the compound eye array 403 are arranged in a honeycomb pattern. Alternatively, the cells of the compound eye array 403 can also be arranged in a matrix or a spiral pattern, as long as the size of each cell in the compound eye array 403 is smaller than the size of each cell in the collimation component 402.

[0113] In another embodiment of this application, the collimation angle of the collimation component 402 (the angle between the collimated light emitted by the light-emitting component and the central axis of the light-emitting component) is -10° to 10°, preferably -5° to 5°, and more preferably -2° to 2°. For example, 1°, 2°, 3°, 4°, 5°, 6°, 7°, 8°, 9°, and 10°.

[0114] Referring to Figure 8, the optical system is equipped with a first mask 805, which permanently reduces the light intensity of a portion of the light emitted by the light-emitting component 801. Figure 8A The optical system includes a light-emitting component 801, a collimating component 802, a first mask 805, and a controller. The light-emitting component 801 is configured to emit light. There are multiple light-emitting components 801 and collimating components 802, with each light-emitting component 801 having one collimating component 802. The collimating component 802 is used to collimate the light emitted by the corresponding light-emitting component 801. The first mask 805 is located between the collimating component 802 and the target plane 804. The controller is electrically connected to each light-emitting component 801 and can control each light-emitting component 801 individually.

[0115] See Figure 8B The optical system includes a light-emitting component 801, a collimating component 802, a first mask 805, a compound eye array 803, and a controller. The light-emitting component 801 is configured to emit light. There are multiple light-emitting components 801 and collimating components 802, with each light-emitting component 801 having one collimating component 802. The collimating component 802 is used to collimate the light emitted by the corresponding light-emitting component 801. The first mask 805 is located between the collimating component 802 and the compound eye array 803. The compound eye array 803 is disposed on the side of the collimating component 802 away from the light-emitting component 801, and is used to diffuse the light passing through the collimating component 802. The light passing through the compound eye array 803 forms an illumination area on the target plane 804. The controller is electrically connected to each light-emitting component 801 and can control each light-emitting component 801 individually.

[0116] See Figure 8CIn some embodiments, the first mask 805 includes a frosted region 822 and a transparent region 821. The transparent region 821 is configured to correspond to the non-overlapping region of the light-emitting component 801, and the frosted region 822 is configured to correspond to the overlapping region to reduce the light intensity of the overlapping region.

[0117] The first mask 805 is configured to permanently reduce the light intensity emitted by the multiple light-emitting components 801. The frosted area 822 reduces the light intensity while the light passes through, and the transparent area 821 allows the light to pass through smoothly. Specifically, the energy distribution curve of the light emitted by the light-emitting component 801 after passing through the collimating component 802 is an isosceles trapezoid, and the frosted area 822 of the first mask 805 modulates the waist region of the isosceles trapezoid.

[0118] Referring to Figure 9, the optical system includes a second mask 906 configured to selectively reduce the light emitted by a plurality of light-emitting components 901. In one embodiment, referring to... Figure 9A The optical system includes a light-emitting component 901, a collimating component 902, a second mask 906, and a controller. The light-emitting component 901 is configured to emit light. There are multiple light-emitting components 901 and collimating components 902, with each light-emitting component 901 having one collimating component 902. The collimating component 902 is used to collimate the light emitted by the corresponding light-emitting component 901. The light passing through the collimating component 902 illuminates the second mask 906. The second mask 906 is a mask structure positioned in front of a target plane 904; after passing through the second mask 906, the light forms an illumination area on the target plane 904. The controller is electrically connected to each light-emitting component 901 and can control each light-emitting component 901 individually. Alternatively, the second mask 906 can be the target plane 904, with the light directly forming an illumination area on the second mask 906 after passing through the collimating component.

[0119] See Figure 9B The optical system includes a light-emitting component 901, a collimating component 902, a compound eye array 903, a second mask 906, and a controller. The light-emitting component 901 is configured to emit light. There are multiple light-emitting components 901 and collimating components 902, with each light-emitting component 901 having one collimating component 902. The collimating component 902 is used to collimate the light emitted by the corresponding light-emitting component 901. The compound eye array 903 is located on the side of the collimating component 902 away from the light-emitting component 901, and is used to diffuse the light passing through the collimating component 902. The second mask 906 is a mask structure in front of the target plane 904. Light passing through the compound eye array 903 illuminates the second mask 906, thus forming an illumination area on the target plane 904. The controller is electrically connected to each light-emitting component 901 and can control each light-emitting component 901 individually. Alternatively, the second mask 906 can be the target plane 904.

[0120] See Figure 9C The optical system includes a light-emitting component 901, a collimating component 902, a first mask 905, a second mask 906, and a controller. The light-emitting component 901 is configured to emit light. There are multiple light-emitting components 901 and collimating components 902, with each light-emitting component 901 having one collimating component 902. The collimating component 902 is used to collimate the light emitted by the corresponding light-emitting component 901. The second mask 906 is a target plane 904. Light rays passing through the collimating component 902 first pass through the first mask 905, where their intensity is permanently reduced before illuminating the second mask 906. The controller is electrically connected to each light-emitting component 901 and can control each light-emitting component 901 individually.

[0121] See Figure 9D The optical system includes a light-emitting component 901, a collimating component 902, a first mask 905, a compound eye array 903, a second mask 906, and a controller. The light-emitting component 901 is configured to emit light. There are multiple light-emitting components 901 and collimating components 902, with each light-emitting component 901 having one collimating component 902. The collimating component 902 is used to collimate the light emitted by the corresponding light-emitting component 901. The compound eye array 903 is disposed on the side of the collimating component 902 away from the light-emitting component 901, and is used to diffuse the light passing through the collimating component 902. The first mask 905 is disposed between the collimating component 902 and the compound eye array 903. The second mask 906 is disposed on the side of the compound eye array 903 away from the collimating component 902. Optionally, the second mask 906 is a mask structure in front of the target plane 904. Light passing through the compound eye array 903 illuminates the second mask 906, and then, after passing through the second mask 906, illuminates the target plane 904 to form an illumination area. The controller is electrically connected to each light-emitting component 901 and can control each light-emitting component 901 individually. Alternatively, the second mask 906 can also be used directly as the target plane, allowing light passing through the compound eye array 903 to directly form a printed image on the second mask 906.

[0122] The second mask 906 allows light to pass through only specific areas, selectively reducing the intensity of local light to form specific patterns and cure the printing material.

[0123] The following figure 10 illustrates the arrangement of the light-emitting components and the splicing of the collimating lenses in the collimating assembly of this application.

[0124] The arrangement of multiple light-emitting components 1001 can be matrix, honeycomb, spiral, or random. The shape of each collimating lens in the collimating component can be square, circular, hexagonal, or other geometric shapes. The array pattern of each lens in the compound eye array is the same as the array pattern of each collimating lens in the collimating component. (See also...) Figure 10AMultiple light-emitting components 1001 are arranged in a square array, and the collimating lens 1011 is rectangular. The light-emitting center of the light-emitting component 1001 coincides with the center of the collimating lens 1011.

[0125] See Figure 10B Multiple light-emitting components 1001 are arranged in a square array, and the collimating lens 1021 is circular. Multiple circular collimating lenses 1021 are arranged in a square array, and the light-emitting center of the light-emitting component 1001 is located at the center of the circular collimating lens 1021.

[0126] Reference Figure 10C and Figure 10D Multiple light-emitting components 1001 are arranged in a staggered, multi-row, multi-column configuration. (See reference...) Figure 10C The collimating lens includes a square lens 1041 and an octagonal lens 1031, with the square lens 1041 located within the gap formed after the octagonal lenses 1031 are joined together. (See also...) Figure 10D The collimating lens is a circular lens, with larger circular lenses 1051 arranged in a square array, and smaller circular lenses 1061 embedded in the gaps between the circular lenses 1051. (See also...) Figure 10E Multiple hexagonal collimating lenses (1071) are joined together. (See reference...) Figure 10F Multiple circular collimating lenses 1081 are randomly arranged, and the light-emitting center of the light-emitting component 1001 is coaxially set with the center of the collimating lens 1081.

[0127] See Figure 11 The optical system includes a light-emitting component 1101, a light-shielding element 1107, a collimating component 1102, and a compound eye array 1103. The light-shielding element 1107 (e.g., a grid) is arranged between the light-emitting component 1101 and the collimating component 1102. The light-shielding element 1107 includes multiple channels, which are arranged one-to-one with the multiple light-emitting components 1101, such that each channel allows only the light emitted by the corresponding light-emitting component 1101 to pass through. The light passing through the channels sequentially passes through the collimating component 1102 and the compound eye array 1103, illuminating the target plane 1104 to form an illumination area. The light intensity of the overlapping area among the multiple light-emitting components 1101 is 80% to 120% of the light intensity of the non-overlapping area.

[0128] The central axis of the channel is coaxial with the central axis of the light-emitting component 1101. Each light-emitting component 1101 uses a light-shielding element 1107 to ensure the desired light projection shape. For example, the light-shielding element 1107 is provided with multiple regular hexagonal channels, and the light emitted by the light-emitting component 1101 forms a regular hexagonal projection area after passing through the channels. In addition, the channels can also be geometric shapes such as triangles, rectangles, regular octagons, and regular decagons.

[0129] The optical system provided in this application embodiment can reduce the interference between light from a single light-emitting component 1101 and light from adjacent light-emitting components 1101 by providing a light-shielding element 1107 between the light-emitting component 1101 and the collimation interval.

[0130] Each light-emitting component 1101 includes at least one LED. The optical system also includes a defect detection device for detecting whether the LED is damaged. The controller controls each light-emitting component 1101 based on the detection information from the defect detection device. In one embodiment, if the defect detection device detects that an LED is damaged, the controller controls the exposure area on the LCD screen to move, replacing the damaged light-emitting component 1101 by illuminating an undamaged light-emitting component 1101. In another embodiment, if the defect detection device detects that an LED is damaged, the controller controls multiple light-emitting components 1101 to move, so that the light-emitting components 1101 corresponding to the exposure area on the LCD screen are all undamaged light-emitting components 1101. In yet another embodiment, if the defect detection device detects that an LED is damaged, the controller controls the light-emitting components 1101 adjacent to the damaged LED to increase their light intensity.

[0131] In another embodiment of this application, the light-emitting component includes multiple LEDs, and the multiple LEDs in the same light-emitting component emit light of the same wavelength. By setting two, three or more LEDs in each light-emitting component, it is ensured that the light-emitting component can still be used normally when one LED fails, avoiding the situation where the light intensity of the display area corresponding to the light-emitting component is essentially zero after the failure of a single LED.

[0132] In another embodiment of this application, the light-emitting component includes a first LED and a second LED. The first LED is used to emit light in a first wavelength band, and the second LED is used to emit light in a second wavelength band. The first wavelength band and the second wavelength band are different.

[0133] Taking ultraviolet light emitted by a light-emitting component as an example, ultraviolet light includes long-wave ultraviolet (UVA), medium-wave ultraviolet (UVB), and short-wave ultraviolet (UVC). UVA has a wavelength range of 315nm to 400nm, UVB has a wavelength range of 280nm to 315nm, and UVC has a wavelength range of 100nm to 280nm. The first LED and the second LED emit ultraviolet light of different wavelengths. For example, the light emitted by the first LED has a center wavelength of 385nm, which belongs to long-wave ultraviolet light; the light emitted by the second LED has a center wavelength of 205nm, which belongs to short-wave ultraviolet light. Combining the two achieves light mixing, improving printing results.

[0134] The optical system provided in this application includes a first LED and a second LED as light-emitting components. The first LED and the second LED emit light in different wavelengths, which can adapt to the printing needs of multiple wavelengths, resulting in more efficient and accurate printing.

[0135] Referring to Figure 12, an optical module provided in this application is described. This optical module is used to realize the functions of the aforementioned optical system. Referring to Figure 12, it includes a mounting plate 1201, a collimating lens array 1203, a grid or light-shielding element 1202, and a controller. The light-shielding element 1202 is located between the mounting plate 1201 and the collimating lens array 1203. The mounting plate 1201 includes multiple light-emitting components, each capable of emitting light. The light-shielding element 1202 has multiple channels, each channel corresponding to one of the multiple light-emitting components. Multiple collimating components 1102 in the collimating lens array 1203 are arranged corresponding to one of the multiple light-emitting components. The controller is electrically connected to the multiple light-emitting components and can individually control the switching of each light-emitting component.

[0136] The light emitted by the light-emitting component is collimated by the collimating lens array 1203 after passing through the channel. The central axis of the light-emitting component is coaxial with the central axis of the channel. Part of the light emitted by the light-emitting component is projected onto the collimating lens array 1203 through the channel, while the rest of the light is blocked, making the boundary of the light source projected onto the collimating lens array 1203 more distinct. Moreover, by setting the light-blocking element 1202, the area of ​​the light spot projected onto the collimating lens array 1203 can be adjusted, making the area of ​​the overlapping region between two adjacent light spots controllable, which helps to control the light intensity of the overlapping region. Optionally, the cross-section of the channel is rectangular, and the light-emitting center of the light-emitting component is located at the center of the rectangle, so that a rectangular light-emitting surface can be obtained with the help of the channel. Alternatively, see [reference needed]. Figure 13 The light-shielding element 1302 is provided with multiple channels 1301, the cross-section of which is a regular hexagon. The light-emitting center of the light-emitting component is located at the center of the regular hexagon, and a regular hexagonal light-emitting surface can be obtained by means of the channel 1301. In addition, the cross-section of the channel can also be triangular, regular octagonal, etc. The embodiments of this application do not specifically limit this.

[0137] The optical module provided in this embodiment has a light-shielding element 1202 between the mounting plate 1201 and the collimating lens array 1203. The light-shielding element 1202 supports the collimating lens array 1203, and multiple channels corresponding to multiple light-emitting components prevent crosstalk between the light-emitting components, making the light source boundary more distinct and the area of ​​the overlapping region of the light spot passing through the collimating component controllable, which helps to improve the exposure quality.

[0138] See Figure 12A , 12BThe compound eye lens array 1204, consisting of 12C and 12D lenses, is positioned on the side of the collimating lens array 1203 away from the light-shielding element 1202. A heat sink 1205 is positioned on the side of the light-emitting component away from the collimating lens array 1203 to cool the light-emitting component. Specifically, the heat sink 1205 includes a plate and heat dissipation fins on one side of the plate. The side of the plate away from the heat dissipation fins is attached to the mounting plate 1201. Heat dissipation gaps are formed between adjacent heat dissipation fins. By setting the heat dissipation fins, the contact area between the heat sink 1205 and the air is increased, improving heat dissipation efficiency. Optionally, the plate and heat dissipation fins are an integral structure made of a material with good thermal conductivity to accelerate heat dissipation and prevent heat accumulation from affecting the lifespan of the optical components.

[0139] See Figure 12E An adapter plate 1206 is mounted beside the mounting plate 1201. The adapter plate 1206 is electrically connected to the mounting plate 1201 to supply power to each light-emitting component. The adapter plate 1206 has circuitry. (See reference...) Figure 12A , 12B In conjunction with 12C, the adapter plate 1206 is parallel to the stacking direction of the mounting plate 1201, the light-shielding element 1202, the collimating lens array 1203, and the compound eye lens array 1204, and is disposed beside the mounting plate 1201. The adapter plate 1206 is connected to an external power supply to power each light-emitting component. The controller is electrically connected to the adapter plate 1206 and controls each light-emitting component through the circuit settings on the adapter plate 1206.

[0140] Figure 14 A photopolymer 3D printing apparatus according to some embodiments is shown. The photopolymer 3D printing apparatus (or additive manufacturing system) includes a drive assembly 1410 and a forming platform 1420. Solid layers are cured layer by layer on the forming platform 1420 to form a printed object. The drive assembly 1410 is capable of driving the forming platform 1420 in a vertical direction based on instructions from a controller (not shown). The photopolymer 3D printing apparatus also includes a carrier 1430, which is in the form of, for example, a trough, box, container, or plate, capable of holding or carrying photosensitive materials of varying viscosities. When the carrier 1430 is, for example, a container, it includes a resilient and at least partially transparent membrane 1432. As the forming platform 1420 moves close to the membrane and stops at a predetermined position, light is provided to cure the photosensitive material to form a current cured layer, which simultaneously adheres to both the forming platform 1420 and the membrane 1432. To continue forming the next cured layer, the forming platform 1420 and the currently cured layer adhered to it move away from the membrane 1432 to release the adhesion between the current cured layer and the membrane. After the forming platform 1420 (and the current cured layer) is peeled off from the film 1432, the forming platform 1420 moves closer to the film to prepare for the formation of the next cured layer. The photopolymer 3D printing apparatus also includes an optical system for providing uniform optical radiation in a predetermined area of ​​the film. Figure 14 The illustrated optical system includes an LCD screen 1440 and an optical module 1450. The optical module 1450 is, for example, the optical module described above, capable of independently controlling the on / off state of each light-emitting component and adjusting the light intensity of each component (e.g., by adjusting the drive current or PWM). The LCD screen 1440 is configured to selectively allow light to pass through. Alternatively, some photopolymer 3D printing equipment includes a DMD assembly in its optical system.

[0141] Figure 15 A photopolymer 3D printing apparatus according to some other embodiments is shown. The photopolymer 3D printing apparatus (or additive manufacturing system) includes a drive assembly 1510 and a forming platform 1520. Solid layers are cured layer by layer on the forming platform 1520 to form a printed object. The drive assembly 1510 is capable of driving the forming platform 1520 to move vertically based on instructions from a controller (not shown). The photopolymer 3D printing apparatus also includes a carrier 1530, which is in the form of, for example, a tank, box, or container, capable of holding or carrying photosensitive materials of different viscosities. The carrier 1530 contains liquid material, and the forming platform 1520 is immersed in the liquid material. When the forming platform 1520 moves close to the liquid surface 1532 of the liquid material and stops at a predetermined position, light is applied to cure the photosensitive material to form the current cured layer, which adheres to the forming platform 1520. To continue forming the next cured layer, the forming platform 1520 moves away from the liquid surface 1532. Afterward, allow the liquid surface to level naturally or use a scraper (not shown) to smooth the liquid surface 1532, thereby ensuring a flat surface for the next cured layer. The photopolymer 3D printing equipment also includes an optical system for providing uniform optical radiation in a predetermined area of ​​the film. Figure 15 The illustrated optical system includes an LCD screen 1540 and an optical module 1550. The optical module 1550 is, for example, the optical module described above, capable of independently controlling the on / off state of each light-emitting component and adjusting the light intensity of each component (e.g., by adjusting the drive current or PWM). The LCD screen 1540 is configured to selectively allow light to pass through. Alternatively, some photopolymer 3D printing equipment includes a DMD assembly in its optical system.

[0142] This application also provides a photopolymerization 3D printing apparatus, including a material tray and an optical system, wherein the optical system is the optical system described in any of the embodiments above. The material tray is used to hold the printing material. The light emitted by the optical system cures the printing material.

[0143] The printing material is a photosensitive resin. The photopolymer 3D printing equipment includes the optical system, material tray, and forming platform as described above. The optical system may include the optical module as described above. The forming platform is connected to a lifting mechanism, which allows the forming platform to move closer to or further away from the material tray.

[0144] like Figure 16 The diagram illustrates, by way of example, a circuit diagram of the optical system of a photopolymer 3D printer provided in an embodiment of this application. The optical system 1600 includes multiple light-emitting components 1601, each including an LED. The controller 1602 of the optical system 1600 includes multiple channels CH1, CH2, ..., CHm1, each channel providing a drive current, and the controller 1602 can independently control each light-emitting component 1601. Figure 16 In this configuration, each LED is electrically connected to at least two (e.g., 2, 3, 4 or more) channels and connected to a first driving voltage V1.

[0145] The total number A1 of light-emitting components 1601 depends, for example, on the build size of the photopolymer 3D printer and the area of ​​the illumination zone of a single light-emitting component 1601. A1 is any number from 100 to 15,000, for example, 100, 170, 200 or 15,000.

[0146] In some embodiments, n channels are provided for the light-emitting component 1601, where n ≥ 2. The number of channels used for different light-emitting components may be different. For example, 3 channels are provided for the first light-emitting component, and 5 channels are provided for the second light-emitting component.

[0147] In some embodiments, the channels provided for the light-emitting component 1601 are redundant. For example, if the light-emitting component has 6 channels, only 4 channels are used during normal operation, and the remaining 2 channels are reserved. In the event of a failure in any normal channel, the LED electrically connected to the failed channel can be connected to the reserved channel.

[0148] In some embodiments, the maximum number of channels electrically connected to a single light-emitting component or a single LED is B1, and the driving current of each channel is I. Then the maximum power of a single light-emitting component or a single LED is P, where P = U1 × (I × B1).

[0149] In practical use, a single LED is electrically connected to a portion of the channels, for example, connecting n channels (n < B1). In this case, the power of the LED is P = U1 × (I × n).

[0150] Figure 16 In the corresponding embodiment, by configuring each LED to be electrically connected to at least two channels of the controller 1602, the higher drive current required for independent control of a single UV LED can be provided by combining the drive currents of at least two channels, thereby satisfying the desired radiant power of the UV LED.

[0151] For example, the single-channel drive current allowed by a single driver chip in a commercially available UV LED is 40mA to 80mA, after, for example... Figure 14 The circuit layout allows the driving current flowing through a single UV LED to range from 160mA to 400mA. By increasing the driving current flowing through a single UV LED, the luminous power of the UV LED is increased.

[0152] like Figure 17 The diagram illustrates, by way of example, a circuit diagram of the optical system of a photopolymer 3D printer provided in an embodiment of this application. The optical system 1700 includes multiple light-emitting components 1701, each of which includes multiple LEDs. The controller 1702 of the optical system 1700 includes multiple channels CH1, CH2, ..., CHm2, each channel being used to provide one drive current, and the controller 1702 is used to independently control each light-emitting component 1701.

[0153] exist Figure 17 In this configuration, each LED is electrically connected to at least two (e.g., 2, 3, 4 or more) channels and connected to a first driving voltage V1.

[0154] The total number A2 of light-emitting components 1701 depends, for example, on the build size of the photopolymer 3D printer and the area of ​​the illumination zone of a single light-emitting component 1701. A2 is, for example, any number from 100 to 15,000, such as 100, 170, 200 or 15,000.

[0155] In some embodiments, n channels are provided for the light-emitting component 1701, where n ≥ 2. The number of channels used for different light-emitting components may be different. For example, 3 channels are provided for each LED in the first light-emitting component, and 5 channels are provided for each LED in the second light-emitting component.

[0156] In some embodiments, the channels provided for the light-emitting component 1701 are redundant. For example, six channels are provided for each LED in the light-emitting component. During normal operation, each LED in the light-emitting component uses only four channels, and the remaining two channels are spares. In the event of a failure in any normal channel, the LED electrically connected to the failed channel can be connected to the spare channel.

[0157] In some embodiments, the maximum number of channels electrically connected to a single LED is B2, and the driving current of each channel is I. Then the maximum power of a single LED is P, where P = U2 × (I × B2).

[0158] In practical use, a single LED is electrically connected to a portion of the channels, for example, connecting n channels (n < B2). In this case, the power of the LED is P = U2 × (I × n).

[0159] In some embodiments, the number of LEDs included in different light-emitting components may be the same or different, and can be configured according to actual needs. For example, two LEDs may be configured for the first light-emitting component and three LEDs may be configured for the second light-emitting component.

[0160] In some embodiments, the maximum number of channels for different LED electrical connections can be the same or different, and can be configured according to actual needs. For example, the maximum number of channels for the first LED electrical connection is B21, and the maximum number of channels for the second LED electrical connection is B22. Figure 17 In the corresponding embodiment, by configuring each LED to be electrically connected to at least two channels of the controller 1702, the higher drive current required for independent control of a single UV LED can be provided by combining the drive currents of at least two channels, thereby satisfying the desired radiant power of the UV LED.

[0161] For example, the single-channel drive current allowed by a single driver chip in a commercially available UV LED is 40mA to 80mA. (The last part, "after, for example...", appears to be incomplete and lacks context.) Figure 15 The circuit layout allows the driving current flowing through a single UV LED to range from 160mA to 400mA. By increasing the driving current flowing through a single UV LED, the luminous power of the UV LED is increased.

[0162] like Figure 18 The diagram illustrates, by way of example, a circuit diagram of the optical system of a photopolymer 3D printer provided in an embodiment of this application. The optical system 1800 includes multiple light-emitting components 1801, each including an LED. The controller 1802 of the optical system 1800 includes multiple channels CH1, CH2, ..., CHm3, each channel providing a drive current, and the controller 1802 independently controls each light-emitting component 1801.

[0163] exist Figure 18 In this circuit, each LED is electrically connected to a current amplifier circuit 1803, and each current amplifier circuit 1803 is electrically connected to a channel and connected to the second driving voltage V2.

[0164] The total number A3 of light-emitting components 1801 depends, for example, on the molding size of the photopolymer 3D printer, and the area A3 of the illumination zone of a single light-emitting component 1601 is, for example, any number from 100 to 15,000, such as 100, 170, 200 or 15,000.

[0165] In some embodiments, n current amplification circuits 1803 are provided for the light-emitting component 1801, where n ≥ 1. The number of current amplification circuits used for different light-emitting components may be different. For example, one current amplification circuit 1803 is provided for the first light-emitting component, and two current amplification circuits 1803 are provided for the second light-emitting component.

[0166] In some embodiments, the channels provided for the current amplifier circuit 1803 are redundant. For example, if two channels are provided for the current amplifier circuit, only one channel is used during normal operation, and the other channel is a spare. In the event of a failure in any normal channel, the current amplifier circuit electrically connected to the failed channel can be connected to the spare channel. In some embodiments, if the maximum current amplification factor of the current amplifier circuit 1803 is E3, and the drive current of each channel is I, then the maximum power of a single LED is P, where P = U2 × (I × E3).

[0167] In practical use, the current amplification factor of the current amplifier circuit 1803 can be adjusted. For example, if the current amplification factor is E31 (E31 < E3), the power of the LED is P = U2 × (I × E31).

[0168] In some embodiments, the maximum current amplification factor of the current amplification circuits for different LED electrical connections can be the same or different, and can be configured according to actual needs. For example, the maximum current amplification factor of the current amplification circuit for the first LED electrical connection is E32, and the maximum current amplification factor of the current amplification circuit for the second LED electrical connection is E33. Figure 18 In the corresponding embodiment, by electrically connecting each LED to at least one current amplifier circuit 1803 and by electrically connecting each current amplifier circuit to at least one channel, the drive current can be amplified by the current amplifier circuit to provide the higher drive current required for independent control of a single UV LED, thereby satisfying the expected radiation power of the UV LED.

[0169] For example, the single-channel drive current allowed by a single driver chip in a commercially available UV LED is 40mA to 80mA, after, for example... Figure 18 The circuit layout allows the driving current flowing through a single UV LED to range from 160mA to 400mA. By amplifying the driving current flowing through a single UV LED using a current amplification circuit, the luminous power of the UV LED is increased.

[0170] like Figure 19The diagram illustrates, by way of example, a circuit diagram of the optical system of a photopolymer 3D printer provided in an embodiment of this application. The optical system 1900 includes multiple light-emitting components 1901, each of which includes multiple LEDs. The optical system 1900 has a controller 1902, which includes multiple channels CH1, CH2, ..., CHm4, each channel providing a drive current. The controller 1902 independently controls each light-emitting component 1901.

[0171] exist Figure 19 In this circuit, each LED is electrically connected to a current amplifier circuit 1903, and each current amplifier circuit 1903 is electrically connected to a channel and connected to the second driving voltage V2.

[0172] The total number A4 of light-emitting components 1901 depends, for example, on the molding size of the photopolymer 3D printer, and the area A4 of the illumination zone of a single light-emitting component 1901 is, for example, any number from 100 to 15,000, such as 100, 170, 200 or 15,000.

[0173] In some embodiments, n current amplification circuits are provided for the light-emitting component, where n ≥ 1. The number of current amplification circuits used for different light-emitting components may be different. For example, two current amplification circuits are provided for the first light-emitting component, and three current amplification circuits are provided for the second light-emitting component.

[0174] In some embodiments, the channels provided for the current amplifier circuit 1903 are redundant. For example, if the current amplifier circuit has three channels, only one channel is used during normal operation, and the remaining two channels are spares. In the event of a failure in any normal channel, the current amplifier circuit electrically connected to the failed channel can be connected to the spare channel.

[0175] In some embodiments, the maximum current amplification factor of each current amplifier circuit 1903 is E4, and the drive current of each channel is I. Then the maximum power of a single LED is P, P = U2 × (I × E4).

[0176] In practical use, the current amplification factor of the current amplifier circuit 1903 can be adjusted. For example, if the current amplification factor is E41 (E41 < E4), the power of the LED is P = U2 × (I × E41).

[0177] In some embodiments, the maximum current amplification factor of the current amplification circuits for different LED electrical connections can be the same or different, and can be configured according to actual needs. For example, the maximum current amplification factor of the current amplification circuit for the first LED electrical connection is E42, the maximum current amplification factor of the current amplification circuit for the second LED electrical connection is E43, and the maximum current amplification factor of the current amplification circuit for the third LED electrical connection is E44.

[0178] Figure 19 In the corresponding embodiment, by electrically connecting each LED to a current amplifier circuit 1903 and electrically connecting each current amplifier circuit to a channel, the drive current can be amplified by the current amplifier circuit to provide the higher drive current required for independent control of a single UV LED, thereby meeting the expected radiation power of the UV LED.

[0179] For example, the single-channel drive current allowed by a single driver chip in a commercially available UV LED is 40mA to 80mA. (The last part, "after, for example...", appears to be incomplete and lacks context.) Figure 19 The circuit layout allows the driving current flowing through a single UV LED to range from 160mA to 400mA. By amplifying the driving current flowing through a single UV LED using a current amplification circuit, the luminous power of the UV LED is increased.

[0180] In applications, the magnitude of the first driving voltage V1, U1, and the magnitude of the second driving voltage V2, U2, can be the same or different, and can be configured according to actual needs. For example, U1 = U2 = 4V.

[0181] like Figure 20 The diagram illustrates, by way of example, a circuit diagram of the optical system of a photopolymer 3D printer provided in an embodiment of this application. The optical system 2000 includes multiple light-emitting components 2001, each of which includes an LED. The controller 2002 of the optical system 2000 includes multiple channels CH1, CH2, ..., CHm5, each channel providing a drive current, and the controller 2002 can independently control each light-emitting component 2001.

[0182] exist Figure 20 In this configuration, each LED comprises multiple cut sub-LED wafers 20011, 20012, and 20013, which are connected in series and electrically connected to a channel of the controller 2002 and connected to a third driving voltage V3.

[0183] The total number A5 of light-emitting components 2001 depends, for example, on the build size of the photopolymer 3D printer and the area of ​​the illumination zone of a single light-emitting component 1801. A5 is any number from 100 to 15,000, for example, 100, 170, 200 or 15,000.

[0184] In some embodiments, n channels are provided for the light-emitting component 2001, where n ≥ 2. The number of channels used for different light-emitting components may be different. For example, 3 channels are provided for the first light-emitting component, and 5 channels are provided for the second light-emitting component.

[0185] In some embodiments, the channels provided for the light-emitting component 2001 are redundant. For example, if the light-emitting component has 6 channels, only 4 channels are used during normal operation, and the remaining 2 channels are reserved. In the event of a failure in any normal channel, the LED electrically connected to the failed channel can be connected to the reserved channel.

[0186] In some embodiments, the maximum number of channels electrically connected to a single light-emitting component or a single LED is B1, and the driving current of each channel is I. Then the maximum power of a single light-emitting component or a single LED is P, where P = U3 × (I × B1).

[0187] In practical use, a single LED is electrically connected to a portion of the channels, for example, connecting n channels (n < B1). In this case, the power of the LED is P = U3 × (I × n).

[0188] Figure 20 In the corresponding embodiment, by making each LED include multiple cut sub-LED wafers connected in series, the driving current required for a single LED is reduced and the driving voltage required for a single LED is increased while the luminous power of a single LED remains unchanged. By making the multiple sub-LED wafers connected in series electrically connected to at least one channel of the controller and connected to a higher driving voltage (i.e., the third driving voltage V3), the required driving current can be provided when a single UV LED is independently controlled, while satisfying the higher driving voltage required by the multiple sub-LED wafers connected in series, thus satisfying the expected radiation power of the UV LED.

[0189] For example, the single-channel drive current allowed by a single driver chip for commercially available UV LEDs is 40mA to 80mA, and the drive voltage of a single UV LED is 4V. (The last part, "after, for example...", appears to be incomplete and possibly contains errors. It's left as is.) Figure 20 With this circuit layout, the allowable drive current for a single channel of a single driver chip can remain constant. By increasing the drive voltage of a single UV LED, the luminous power of the UV LED is increased.

[0190] like Figure 21The diagram illustrates, by way of example, a circuit diagram of the optical system of a photopolymer 3D printer provided in an embodiment of this application. The optical system 2100 includes multiple light-emitting components 2101, each of which includes multiple LEDs. The controller 2102 includes multiple channels CH1, CH2, ..., CHm6, each channel being used to provide one drive current, and the controller 2102 is capable of independently controlling each light-emitting component 2101.

[0191] exist Figure 21 In this configuration, each LED comprises multiple cut sub-LED wafers connected in series and electrically connected to a channel of controller 2102 and connected to a third driving voltage V3.

[0192] The total number A6 of light-emitting components 2101 depends, for example, on the molding size of the photopolymer 3D printer and the area of ​​the illumination zone of a single light-emitting component 2101. A6 is any number from 100 to 15,000, for example, 100, 170, 200 or 15,000.

[0193] In some embodiments, n channels are provided for the light-emitting component 2101, where n ≥ 2. The number of channels used for different light-emitting components may be different. For example, 3 channels are provided for the first light-emitting component, and 5 channels are provided for the second light-emitting component.

[0194] In some embodiments, the channels provided for the light-emitting component 2101 are redundant. For example, if the light-emitting component has 6 channels, only 4 channels are used during normal operation, and the remaining 2 channels are reserved. In the event of a failure in any normal channel, the LED electrically connected to the failed channel can be connected to the reserved channel.

[0195] In some embodiments, the maximum number of channels electrically connected to a single light-emitting component or a single LED is B2, and the driving current of each channel is I. Then the maximum power of a single light-emitting component or a single LED is P, where P = U3 × (I × B2).

[0196] In practical use, a single LED is electrically connected to a portion of the channels, for example, connecting n channels (n < B2). In this case, the power of the LED is P = U3 × (I × n).

[0197] In some embodiments, the number of LEDs included in different light-emitting components may be the same or different, and can be configured according to actual needs. For example, two LEDs may be configured for the first light-emitting component and three LEDs may be configured for the second light-emitting component.

[0198] In some embodiments, the maximum number of channels for different LED electrical connections can be the same or different, and can be configured according to actual needs. For example, the maximum number of channels for the first LED electrical connection is B21, and the maximum number of channels for the second LED electrical connection is B22.

[0199] Figure 21 In the corresponding embodiments, by making each LED include multiple cut sub-LED wafers connected in series, the required driving current for a single LED is reduced and the required driving voltage for a single LED is increased while maintaining the same luminous power of the individual LED. By electrically connecting the series-connected sub-LED wafers to at least one channel of the controller and applying a high driving voltage (i.e., the third driving voltage V3), the required driving current can be provided for independent control of a single UV LED while satisfying the higher driving voltage required by the series-connected sub-LED wafers, thus meeting the desired radiant power of the UV LED, without increasing the driving current of a single channel. For example, the permissible driving current for a single channel of a commercially available UV LED driver chip is 40mA to 80mA, and the driving voltage for a single UV LED is 4V. After, for example... Figure 21 With this circuit layout, the allowable drive current for a single channel of a single driver chip can remain constant. By increasing the drive voltage of a single UV LED, the luminous power of the UV LED is increased.

[0200] In some embodiments, the magnitude of the third driving voltage V3, U3, is greater than the magnitude of the first driving voltage V1, U1, and the magnitude of the second driving voltage V2, U2, i.e., U3 > U1 and U3 > U2. With the maximum luminous power P of a single LED remaining constant and the maximum driving current I that a single channel can provide remaining constant, U3 = U1 × B2 = U2 × E4. Considering the potential power loss of multiple sub-LED wafers connected in series relative to an uncut single LED, U3 can be set to be greater than U1 × B2, where U1 × B2 = U2 × E4. In some embodiments, in the same optical system, each LED can adopt any of the above configurations, and different LEDs can adopt different configurations. That is, multiple different configurations can coexist in the same optical system, and the choice can be made according to actual needs such as cost, process complexity, and size, resulting in high configuration flexibility.

[0201] In the above embodiments, the maximum luminous power P of the LED and the maximum drive current I that each channel of the controller can provide are inherent operating performance parameters of the LED and the controller, respectively, and are determined by the type and performance of the LED and the controller selected by the user.

[0202] In some embodiments, each light-emitting component includes a plurality of LEDs that emit ultraviolet light, the plurality of ultraviolet-emitting LEDs including a first LED and a second LED, wherein the emission wavelength of the first LED is different from that of the second LED. Alternatively, each light-emitting component includes a plurality of LEDs that emit ultraviolet light, the plurality of ultraviolet-emitting LEDs including a first LED and a second LED, wherein the emission wavelength of the first LED is the same as that of the second LED.

[0203] In this embodiment, by configuring multiple LEDs with different emission wavelengths within the illumination zone defined by the same light-emitting component, the optical system can project patterns of multiple wavelengths onto the printing material in a time-sharing or simultaneous manner, which can meet the printing requirements of different materials or different processes, and the emission wavelength of the optical system can be switched without replacing the light-emitting plate.

[0204] In some embodiments, a plurality of LEDs with the same emission wavelength include a primary LED and at least one corresponding backup LED.

[0205] In some embodiments, by arranging multiple LEDs with the same emission wavelength within an illumination zone defined by the same light-emitting component, one of the LEDs is designated as the primary LED and the remaining LEDs are designated as corresponding backup LEDs. This ensures that when the primary LED or some of the backup LEDs are detected as faulty, the remaining backup LEDs can be lit to guarantee the continuity of illumination.

[0206] In applications, any light-emitting component may include a primary LED with the same emission wavelength and at least one corresponding backup LED. The emission wavelengths of the primary LED and the corresponding backup LED may be in the ultraviolet (UV) or blue light band. The UV and blue light bands can be set according to actual needs; for example, the center wavelength of the UV band may be 405 nm or 385 nm.

[0207] like Figure 22 As shown, an exemplary schematic diagram of the current amplification circuit provided in the embodiment of this application is illustrated, wherein the current amplification circuit 2200 includes a first resistor unit 2201, a second resistor unit 2202, and a transistor unit 2203;

[0208] The first end of the first resistor unit 2201 is electrically connected to the input end of the transistor unit 2203 and connected to the second driving voltage V2; the second end of the first resistor unit 2201 is electrically connected to the first end of the second resistor unit 2202 and connected to the driving current Iset.

[0209] The second terminal of the second resistor unit 2202 is electrically connected to the controlled terminal of the transistor unit 2203;

[0210] The output of transistor unit 2203 is electrically connected to an LED.

[0211] In applications, both the first resistor unit 2201 and the second resistor unit 2202 can be implemented using a single resistor or multiple resistors connected in series. The transistor unit 2203 can be implemented using a bipolar junction transistor (BJT) or a field-effect transistor (FET). The BJT transistor can be a PNP transistor or an NPN transistor, and the FET transistor can be an N-channel junction field-effect transistor (JFET), a P-channel JFET, an N-channel metal-oxide-semiconductor field-effect transistor (MOSFET), a P-channel MOSFET, an enhancement-mode MOSFET, or a depletion-mode MOSFET.

[0212] like Figure 23 As shown, an exemplary schematic diagram of a second structure of the current amplification circuit provided in the embodiments of this application is illustrated. In this circuit, the first resistor unit 2301 includes a first resistor R1, the second resistor unit 2302 includes a second resistor R2, and the transistor unit 2303 includes a PNP transistor Q1. The emitter, base, and collector of the PNP transistor Q1 respectively constitute the input terminal, the controlled terminal, and the output terminal of the transistor unit 2303.

[0213] like Figure 24 As shown, an exemplary schematic diagram of the power supply circuit in the optical system provided in this application embodiment is illustrated. The power supply circuit 2400 includes multiple step-down circuits 2401, 2402, and 2403, such as DC-DC (direct current to direct current) step-down circuits. The multiple DC-DC step-down circuits 2401, 2402, and 2403 are respectively used to convert the input power supply voltage Vin into driving voltages Vout1, Vout2, ..., Vout3.

[0214] In applications, since all LEDs in the optical system are essentially connected in parallel, the required total current is relatively high. If only one or a few DC-DC buck circuits are used to provide the driving voltage, the circuit may overheat due to the excessive current that a single DC-DC buck circuit needs to handle. Therefore, multiple DC-DC buck circuits are needed to distribute the large current and achieve overcurrent and overheat protection. In addition, since the DC-DC buck circuits also have a voltage reduction function, they can achieve overvoltage protection. The total number of DC-DC buck circuits can be set according to the current handling capacity of the DC-DC buck circuits, with a minimum of two, i.e., n≥2.

[0215] In applications, each DC-DC step-down circuit can be implemented using a DC-DC step-down chip. Different DC-DC step-down circuits can use the same or different types of DC-DC step-down chips.

[0216] In applications, the power supply voltage Vin can be configured to any voltage greater than the driving voltage required by each LED in the optical system, depending on actual needs. For example, the power supply voltage Vin can be 24V.

[0217] In applications, depending on the configuration of each LED in the optical system, the driving voltages Vout1, Vout2, and Vout3 output by the multiple step-down circuits 2401, 2402, and 2403 may include at least one of a first driving voltage V1, a second driving voltage V2, and a third driving voltage V3. For example, in the configuration of optical systems 1600 or 1700, Vout1 = Vout2 = Vout3 = V1. For example, in the configuration of optical systems 1800 or 1900, Vout1 = Vout2 = Vout3 = V2. For example, in the configuration of optical systems 2000 or 2100, Vout1 = Vout2 = Vout3 = V3.

[0218] like Figure 25 As shown, an exemplary schematic diagram of the buck circuit provided in an embodiment of this application is illustrated. The buck circuit 2500 includes a buck circuit 2501 (e.g., a DC-DC buck circuit) and a voltage regulating circuit 2502;

[0219] The buck circuit consists of an input capacitor, a 2503 power controller chip, a high-voltage side switch transistor, a low-voltage side switch transistor, an inductor, and an output capacitor, connected in a Buck buck topology.

[0220] The input terminal of the input capacitor and the input terminal VIN of the power controller chip 2503 are connected to the power supply voltage Vin, and the output terminal of the input capacitor is grounded.

[0221] The high-voltage side pin HO of the power controller chip 2503 is electrically connected to the controlled terminal of the high-voltage side switching transistor. The voltage output pin LX of the power controller chip 2503 is electrically connected to the output terminal of the high-voltage side switching transistor, one end of the inductor, and the input terminal of the low-voltage side switching transistor. The low-voltage side pin LO of the power controller chip 2503 is electrically connected to the controlled terminal of the low-voltage side switching transistor. The feedback pin FB of the DC-DC power controller chip 2503 is electrically connected to the second terminal of resistor R2 and the first terminal of R4. The ground terminal GND of the power controller chip 2503 is grounded.

[0222] The input terminal of the high-voltage side switching transistor is connected to the power supply voltage Vin;

[0223] The output terminal of the low-voltage side switching transistor is grounded;

[0224] The second end of the inductor is electrically connected to the input end of the output capacitor and the first end of the resistor R1 to provide the drive voltage Vout;

[0225] The output terminal of the output capacitor is grounded;

[0226] The second terminal of resistor R1, the first terminal of resistor R2, and the first terminal of resistor R4 are electrically connected, and the second terminal of resistor R3 is grounded.

[0227] The voltage regulation circuit 2502 consists of a PWM / DAC voltage regulation unit 2504 and a processor 2505;

[0228] The input terminal of the PWM / DAC voltage regulation unit 2504 is electrically connected to the processor 2505, and the output terminal Vset of the PWM / DAC voltage regulation unit 2504 is electrically connected to the second terminal of the resistor R4.

[0229] Since the voltage at the feedback pin FB of the DC-DC power controller chip 2503 remains essentially constant, typically 0.6V or 0.8V, depending on the internal voltage reference, and Vout and Vfb are generally in a fixed multiple relationship through a voltage divider connected in series with two resistors, the output Vout is constant. The required adjustment range of Vout is calculated using LED voltage parameter information. Based on the voltage variation range of the introduced DAC / PWM voltage regulation unit 2304, the values ​​of R1, R2, R3, and R4 are determined. This allows for dynamic adjustment of the multiple relationship between Vout and Vfb, ultimately adjusting the value of Vout.

[0230] In the application, the step-down circuit 2500 is any one of multiple step-down circuits 2501, 2102, and 2203, that is, Vout is equal to any one of Vout1, Vout2, and Vout5.

[0231] In this embodiment, by employing multiple DC-DC step-down circuits to convert a large power supply voltage into a smaller driving voltage required by each LED in the optical system, overheat protection, overcurrent protection, and overvoltage protection functions can be achieved while providing driving voltage.

[0232] like Figure 26 As shown, an exemplary circuit diagram of the optical system of the photopolymer 3D printer provided in the embodiments of this application is illustrated, wherein the optical system 2600 includes a processor 2603 electrically connected to a controller 2601 and a power supply circuit 2602;

[0233] The controller 2601 is used to control the drive current Iset of each channel according to the instructions given by the processor 2603. When the drive voltage Vout associated with any channel is lower than the corresponding first preset voltage, it indicates that the drive current Iset of the channel is too large and the drive voltage Vout output by the power supply circuit 2602 is too low. A corresponding low voltage warning signal needs to be output to the processor 2603. When the drive voltage Vout associated with any channel is higher than the corresponding second preset voltage, it indicates that the drive current Iset of the channel is too small and the drive voltage Vout output by the power supply circuit 2602 is too high. A corresponding high voltage warning signal needs to be output to the processor 2603.

[0234] Processor 2603 is used to control the pulse width modulation (PWM) voltage regulation signal or digital-to-analog converter (DAC) voltage regulation signal output to power supply circuit 2602 according to each low voltage warning signal, so as to increase the drive voltage Vout output by power supply circuit 2602; and to control the PWM voltage regulation signal or DAC voltage regulation signal output to power supply circuit 2602 according to each high voltage warning signal, so as to decrease the drive voltage Vout output by power supply circuit 2602.

[0235] In applications, controller 2601 can be Figures 16-21 Any controller in, Figure 26 The example shows the drive current Iset of any channel in controller 2601 and the drive voltage Vout output by power supply circuit 2602, where Vout can be any one of Vout1, Vout2, and Vout3.

[0236] It should be understood that, based on Figures 16-21 The configuration of each channel in any controller is as follows: each channel is not directly connected to the drive voltage Vout, but is connected to the drive voltage Vout through LEDs, current amplification circuits, or multiple sub-LED wafers connected in series; among them, the redundant channel has no signal input, and the drive current Iset of the redundant channel is 0A.

[0237] In applications, the required drive voltage Vout of the power supply circuit 2602 can be calculated in advance based on Ohm's law, according to the drive current Iset of each channel and the equivalent resistance of each load (i.e., LED, current amplifier circuit, multiple sub-LED wafers in series, loss resistance of wires, etc.) under the configuration of that channel.

[0238] In applications, while keeping the driving voltage Vout constant, the processor 2603 can control the driving current Iset output by each channel of the controller 2601 via software control methods to adjust the luminous power of the corresponding LEDs. The software control method is implemented based on a computer program running in the processor 2603. Users can interact with the processor 2603 through any human-computer interaction method to adjust the luminous power of each LED. The processor 2603 can also automatically control the luminous power of each LED according to printing requirements.

[0239] like Figure 27 As shown, an exemplary circuit diagram of the optical system of a photopolymer 3D printer provided in an embodiment of this application is illustrated. The optical system 2700 includes a processor 2702 electrically connected to a controller 2701;

[0240] The controller 2701 is used to determine whether each channel is short-circuited or open-circuited based on the drive current Iset of each channel. If any channel is short-circuited, it outputs a corresponding short-circuit signal to the processor 2702. If any channel is open-circuited, it outputs a corresponding open-circuit signal to the processor 2702.

[0241] The processor 2702 is used to locate the LEDs of the corresponding channel electrical connections as bad pixels based on short-circuit signals or open-circuit signals, so as to realize bad pixel detection.

[0242] In application, controller 2701 can determine that a channel is short-circuited when the drive current Iset of any non-redundant channel is greater than I+ΔI, and determine that the channel is open-circuited when the drive current Iset of any non-redundant channel is 0A, where ΔI is the maximum allowable error of the maximum drive current I that the channel can provide.

[0243] In the application, the processor 2702 can locate the position of the LED connected to the corresponding channel and mark it as a bad point when it receives a short circuit signal or an open circuit signal, so as to realize bad point detection.

[0244] In one embodiment, the processor 2702 is further configured to enable a corresponding backup LED if any primary LED is identified as a dead pixel.

[0245] In the case where at least one spare LED comprises multiple spare LEDs and some spare LEDs are identified as dead pixels, one remaining spare LED is activated.

[0246] In applications where at least one light-emitting component includes multiple LEDs with the same emission wavelength, and these multiple LEDs with the same emission wavelength include a primary LED and at least one corresponding backup LED, the processor 2702 can control the controller 2701 to provide a drive current Iset to the corresponding backup LED to enable (i.e., light up) the corresponding backup LED if any primary LED is identified as a dead pixel. If at least one backup LED includes multiple backup LEDs, and if a activated backup LED is also defined as a dead pixel, the processor 2702 controls the controller 2701 to provide a drive current Iset to the next backup LED to enable the next backup LED, and so on, until any primary LED and all its corresponding backup LEDs are detected as dead pixels. At this point, a corresponding dead pixel alarm signal can be issued through any electrically connected human-machine interface device to remind the user. The user can choose to replace the light-emitting board or replace or repair the dead pixel.

[0247] like Figure 28 As shown, an exemplary circuit diagram of the optical system of a photopolymer 3D printer provided in an embodiment of this application is illustrated. The optical system 2800 includes:

[0248] Light-emitting panel 2801, with multiple light-emitting components arranged in an array on light-emitting panel 2801;

[0249] Processor 2802, electrically connected to controller 2603, is used for:

[0250] In the direct current (DC) dimming mode, the controller 2803 outputs analog current signals of different magnitudes to each LED. The light intensity acquisition device 2804 acquires the light intensity of each LED under different magnitude analog current signals. Based on the different magnitude analog current signals and the light intensity of each LED under different magnitude analog current signals, the power-current relationship between the power of the light-emitting panel 2801 and the magnitude of the analog current signal is fitted.

[0251] In PWM dimming mode, the controller 2803 outputs PWM signals with different duty cycles to each LED, and the light intensity of each LED under different duty cycles is obtained based on the light intensity acquisition device 2804.

[0252] Based on the power-current relationship, PWM signals with different duty cycles, and the light intensity of each LED under PWM signals with different duty cycles, the power of each LED under PWM signals with different light intensities is obtained, so as to obtain the PWM value-power relationship between the power of each LED and the duty cycle of the PWM signal.

[0253] In the hybrid dimming mode, based on the target power and the PWM value-power relationship between the power of each LED and the duty cycle of the PWM signal, the controller 2803 controls the magnitude of the analog current signal output to the light-emitting board 2801 and the duty cycle of the PWM signal of each LED to adjust the light intensity of the light-emitting board 2801 and keep the light intensity of each LED consistent.

[0254] In applications, the light intensity acquisition device 2804 can be an image capture device (e.g., a camera or any device with a camera) or a contact probe (e.g., a photometer).

[0255] In the application, the processor 2802 can first plot the light intensity-current curve (i.e., PI curve) of a single LED based on analog current signals of different magnitudes and the light intensity of a single LED under analog current signals of different magnitudes. For example, if the light-emitting board 2801 includes A LEDs, then A PI curves need to be plotted. Then, the power-current relationship between the power of the light-emitting board 2801 and the magnitude of the analog current signal is obtained by fitting the A PI curves. Alternatively, the processor 2802 can first plot the light intensity-current curves of multiple LEDs based on analog current signals of different magnitudes and the light intensity of multiple LEDs under analog current signals of different magnitudes. For example, if the light-emitting board 2801 includes B groups of LEDs, and each group of LEDs includes multiple LEDs, then B PI curves need to be plotted. Then, the power-current relationship between the power of the light-emitting board 2801 and the magnitude of the analog current signal is obtained by fitting the B PI curves.

[0256] In the application, the processor 2802 can establish a correspondence between PWM signals with different duty cycles and the light intensity of each LED under the PWM signals with different duty cycles, and store this correspondence in memory. Specifically, the correspondence can exist in the form of a correspondence table. Based on this correspondence, when it is necessary to adjust the light intensity of multiple LEDs to a consistent preset light intensity, the processor 2802 can determine the duty cycle of the PWM signal required for each LED under the preset light intensity according to the preset light intensity and the correspondence, and drive each LED based on the duty cycle of the PWM signal required for each LED under the preset light intensity, so as to adjust the light intensity of multiple LEDs to be consistent and achieve calibration of the light intensity differences between different LEDs.

[0257] In applications, the processor in the above embodiments can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0258] In applications, memory may be an internal storage unit of the processor in some embodiments, such as RAM. In other embodiments, memory may be an external storage device electrically connected to the processor, such as a plug-in hard disk, a smart media card (SMC), a secure digital card (SD), or a flash card. Furthermore, memory may include both internal and external storage units. Memory is used to store operating systems, applications, boot loaders, data, and other programs, such as program code for computer programs. Memory can also be used to temporarily store data that has been output or will be output.

[0259] The optical system of this application is applied to a photopolymer 3D printing device or an additive manufacturing system. The photopolymer 3D printing device includes a drive assembly and a forming platform. Solid layers are cured layer by layer on the forming platform to form a printed object. The drive assembly can drive the forming platform to move vertically based on instructions from a controller. The photopolymer 3D printing device also includes a support device, which is in the form of, for example, a trough, box, container, or plate, capable of holding or carrying photosensitive materials of different viscosities. When the support device is, for example, a container, it includes a resilient and at least partially transparent membrane. As the forming platform moves closer to the membrane and stops at a predetermined position, light is provided to cure the photosensitive material to form a current cured layer, which simultaneously adheres to both the forming platform and the membrane. To continue forming the next cured layer, the forming platform and the currently cured layer adhered to it move away from the membrane to release the adhesion between the current cured layer and the membrane. After the forming platform (and the current cured layer) peels off from the membrane, the forming platform moves closer to the membrane to prepare for the formation of the next cured layer. The photopolymer 3D printing device also includes an optical system for providing uniform optical radiation in a predetermined area of ​​the membrane. One optical system includes an LCD screen and an optical module. The optical module can independently control the opening and closing of each light-emitting component, and can also adjust the light intensity of each component (e.g., by adjusting the drive current or PWM). The LCD screen is configured to selectively allow light to pass through. Alternatively, the optical system of some photopolymer 3D printing equipment includes a DMD assembly.

[0260] The optical system of this application can also be applied to photopolymer 3D printing equipment in other embodiments. The photopolymer 3D printing equipment (or additive manufacturing system) includes a drive assembly and a forming platform. Solid layers are cured layer by layer on the forming platform to form a printed object. The drive assembly can drive the forming platform to move vertically based on instructions from a controller (not shown). The photopolymer 3D printing equipment also includes a carrier, which is, for example, in the form of a tank, box, or container, capable of holding or carrying photosensitive materials of different viscosities. The carrier contains liquid material, and the forming platform is immersed in the liquid material. When the forming platform moves close to the surface of the liquid material and stops at a predetermined position, light is provided to cure the photosensitive material to form the current cured layer, which adheres to the forming platform. To continue forming the next cured layer, the forming platform moves away from the liquid surface. Thereafter, the liquid surface is allowed to level naturally or a scraper (not shown) is used to smooth the liquid surface, thereby ensuring a flat surface for the next cured layer. The photopolymer 3D printing equipment also includes an optical system for providing uniform optical radiation in a predetermined area of ​​the film. The optical system includes an LCD screen and an optical module. The optical module, such as the one described above, is capable of independently controlling the on / off state of each light-emitting component and adjusting the light intensity of each component (e.g., by adjusting the drive current or PWM). The LCD screen is configured to selectively allow light to pass through. Alternatively, the optical systems of some photopolymer 3D printing equipment include DMD components.

[0261] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0262] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0263] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. An optical system for a photopolymer 3D printer, characterized in that, include: Multiple light-emitting components, each of which includes one or more LEDs that emit ultraviolet light; as well as A controller comprising multiple channels, each channel being configured to provide a drive current, the controller being configured to independently control each of the light-emitting components; The LED of the light-emitting component is configured as any one of the following: At least two of the channels are electrically connected and a first driving voltage is applied, the driving currents of at least two of the channels are combined and used to drive a single LED, wherein the power of a single LED is P = U1 × (I × n), U1 is the first driving voltage, I is the driving current of each channel, and n is the number of channels connected to a single LED, n ≥ 2; An electrical connection current amplification circuit is provided, which is electrically connected to at least one of the channels and connected to a second driving voltage to amplify the driving current and drive a single LED. The power of the single LED is P = U2 × (I × E31), where U2 is the second driving voltage, I is the driving current for each channel, and E31 is the current amplification factor of the current amplification circuit. The device comprises multiple sub-LED wafers that have been cut and connected in series. The multiple sub-LED wafers are electrically connected to at least one channel and connected to a third driving voltage to drive a single LED. The power of a single LED is P = U3 × (I × n), where U3 is the third driving voltage, I is the driving current of each channel, and n is the number of channels connected to a single LED, n ≥ 2. The third driving voltage is greater than the first driving voltage and the second driving voltage. Among them, while the driving current of a single channel of a single driving chip remains unchanged, the luminous power of a single LED is increased by at least one of the following methods: merging the driving current of at least two channels to amplify the driving current flowing through the single LED, or increasing the driving voltage of the single LED. The current amplification circuit includes a first resistor unit, a second resistor unit, and a transistor unit. The first end of the first resistor unit is electrically connected to the input terminal of the transistor unit and is connected to the second driving voltage; the second end of the first resistor unit is electrically connected to the first end of the second resistor unit and is connected to the driving current. The second terminal of the second resistor unit is electrically connected to the controlled terminal of the transistor unit; The output terminal of the transistor unit is electrically connected to an LED.

2. The optical system as described in claim 1, characterized in that, It also includes a power supply circuit, which includes multiple step-down circuits, each of which is used to convert the input power supply voltage into a driving voltage, wherein the driving voltage is the first driving voltage, the second driving voltage, or the third driving voltage.

3. The optical system as described in claim 2, characterized in that, The step-down circuit includes a DC-DC step-down circuit and a voltage regulation circuit.

4. The optical system as described in claim 2, characterized in that, It also includes a processor, wherein when the drive voltage associated with the channel is lower than a first preset voltage, the controller outputs a low-voltage warning signal to the processor, and the processor is configured to increase the drive voltage of the LED associated with the channel based on the low-voltage warning signal; and / or When the driving voltage associated with the channel is higher than a second preset voltage, the controller outputs a high-voltage warning signal to the processor, which is configured to reduce the driving voltage of the LED associated with the channel based on the high-voltage warning signal.

5. The optical system according to any one of claims 1 to 4, characterized in that, The controller is configured as follows: When a short circuit is determined in the channel based on the drive current voltage of the channel, a short circuit signal is output; and / or When it is determined that the channel is open-circuited based on the drive current of the channel, an open-circuit signal is output.

6. The optical system as claimed in claim 1, characterized in that, The controller is configured to adjust the current or PWM of the light-emitting component.

7. The optical system as claimed in claim 1, characterized in that, The plurality of LEDs emitting ultraviolet light include: A first LED and a second LED, wherein the emission wavelength of the first LED is different from that of the second LED; or The first LED and the second LED have the same emission wavelength.

8. A photopolymerization 3D printer, characterized in that, include: A molding platform configured to adhere at least one cured layer; A support device configured to support printing material; A drive assembly configured to drive the molding platform to move closer to or away from the support device; and The optical system according to any one of claims 1 to 7, wherein the ultraviolet light emitted by the optical system is configured to cure the printing material to form the cured layer.

9. A method for operating a photopolymer 3D printer as described in claim 8, characterized in that, include: The optical system emits light using a first plurality of light-emitting components to project ultraviolet light onto the printing material in the carrier device to form a first cured layer having a first contour; Then The optical system uses a second plurality of light-emitting components to emit light, projecting ultraviolet light onto the printing material in the carrier device to form a second cured layer with a second contour. The first plurality of light-emitting components are different from the second plurality of light-emitting components.

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