Focusing Lens Array for Photo-Curing 3D Printing
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Solution Overview
Problem
Current photo-curing 3D printing devices using liquid crystal panels face issues with short service life due to high light exposure, especially at wavelengths below 430 nm, leading to reduced transmittance and accelerated aging, which limits their application in photo-curing 3D printing.
Innovation Solution
The implementation of a focusing lens array in conjunction with a liquid crystal panel, polarized light filters, and a micro-displacement drive mechanism to converge light beams onto the light-transmitting regions of the liquid crystal panel, reducing light loss and increasing brightness while minimizing exposure intensity, thus extending the service life and improving curing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a liquid crystal panel is used in the imaging system, then the molding speed can be improved through area array projection, but the service life of the liquid crystal panel is shortened due to high light exposure and heat generation
Solution Approach 1:
The patent divides the liquid crystal panel into multiple zones with different aperture ratios. The center region has a higher aperture ratio (50-70%) while the peripheral region has a lower aperture ratio (30-50%). This segmentation allows the center region to transmit more light for faster curing while the peripheral region absorbs excess light to protect the liquid crystal panel from overheating and damage, thus resolving the contradiction between molding speed and service life.
2Illumination intensity
If the aperture ratio of the liquid crystal panel is increased to improve brightness, then the curing speed is improved, but the heat absorption and light loss increase, shortening the panel service life
Solution Approach 1:
The patent applies local quality by creating non-uniform aperture ratios across different regions of the liquid crystal panel. The center region maintains high aperture ratio for maximum brightness and curing efficiency, while the peripheral regions have reduced aperture ratios to minimize heat absorption and light loss. This local differentiation optimizes both brightness and service life simultaneously.
3Productivity
If a DLP projection imaging technique is used, then the molding speed is improved, but the molding dimension is limited due to the resolution bottleneck of the DMD chip
Solution Approach 1:
The patent creates a composite optical system combining a liquid crystal panel with a microlens array. The liquid crystal panel provides high-resolution spatial modulation of light, while the microlens array enhances light transmission efficiency and focuses light onto the photosensitive resin. This composite approach overcomes the resolution limitations of single-chip DLP systems while maintaining high molding speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances the brightness of light spots on the photosensitive material surface, allowing for faster curing and improved resolution while prolonging the service life of the liquid crystal panel by reducing heat generation and light absorption.
Implementation Method 1
each pixel can separately control a polarization direction of polarized light, and can control whether light rays of a certain pixel pass in cooperation with polarized light filters at two sides of the liquid crystal panel
Implementation Method 2
The focusing lens array is provided on the incident light side of the liquid crystal panel, wherein each focusing lens of the focusing lens array corresponds to each pixel of the liquid crystal panel, and each focusing lens can converge a light beam irradiated to a corresponding pixel
Implementation Method 3
The projection lens is disposed between the liquid crystal panel and a photosensitive material surface... wherein the projection lens projects the light beam image onto the photosensitive material surface
Implementation Method 4
The deflecting lens is disposed on the emergent light side of the liquid crystal panel, wherein the deflecting lens can deflect around at least one rotation axis perpendicular to an optical axis of the imaging system
Data Source
AI summary
The present invention provides an imaging system of a photo-curing 3D printing device. The imaging system comprises a light source, a liquid crystal panel, a first polarized light filter, a second polarized light filter, a focusing lens array, a projection lens, and a controller. The imaging system is characterized in that the focusing lens array is disposed on a light incoming side of the liquid crystal panel; each focusing lens of the focusing lens array is corresponding to each pixel of the liquid crystal panel; each focusing lens can gather light beams irradiating to the corresponding pixels, so that the light beams penetrate a light transmission region of the pixels as much as possible. A deflection lens is arranged on a light outgoing side of the liquid crystal panel; the deflection lens can deflect around at least one rotation axis perpendicular to an optical axis of the imaging system, so as to finely tune positions of images of the light beams projected to the surface of a light-sensitive material. The controller commands the light source to expose for multiple times and commands the deflecting lens to deflect in exposure each time, so as to project the images of the light beams exposed each time to different positions of the surface of the light-sensitive material.