LED Illumination Array with Levelling Surface for Stereolithography
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Solution Overview
Problem
Manufacturing a reliable and economical illumination system for stereolithography that achieves high accuracy and brightness with well-defined image spots, while maintaining a high numerical aperture, is challenging due to sensitivity of image spot dimensions to precise LED positions.
Innovation Solution
The solution involves a two-dimensional array of LEDs with individually controlled electrical pathways and a levelling surface for precise positioning, using bare dies for improved positional accuracy and a thermally conductive support body to manage heat and extend LED lifespan, allowing for efficient production and high-resolution imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a high numerical aperture optical system is used to achieve sufficient brightness and well-defined image spots, then illumination intensity and image quality are improved, but sensitivity to LED position variations increases, making manufacturing more difficult
Solution Approach 1:
A levelling surface is introduced as an intermediary component between the LED array and the optical system. This levelling surface compensates for position variations of individual LEDs, acting as a mediator that decouples the sensitivity of the high numerical aperture optical system from manufacturing tolerances of the LED positions, thereby maintaining image spot quality without requiring extremely precise LED placement
Solution Approach 2:
The patent changes the physical state or parameters of the LED array by introducing a levelling surface that actively compensates for position variations. This parameter adjustment allows the system to maintain optimal performance with relaxed manufacturing tolerances, resolving the contradiction between achieving high brightness through high numerical aperture and maintaining manufacturing feasibility
2Manufacturing precision
If a high numerical aperture is used to achieve high accuracy and brightness, then image spot quality is improved, but the system becomes more sensitive to LED position variations, increasing device complexity
Solution Approach 1:
The levelling surface serves as a compensating intermediary that reduces system sensitivity to LED position variations. By introducing this intermediate component, the patent simplifies the overall system robustness without sacrificing image spot accuracy, allowing high numerical aperture operation with standard manufacturing tolerances
3Ease of manufacture
If conventional LED mounting methods are used, then ease of manufacture is maintained, but positional accuracy and thermal management are insufficient for high numerical aperture applications
Solution Approach 1:
The patent segments the LED array into individual LED units that are separately mounted onto the levelling surface. This segmentation allows each LED to be positioned and adjusted independently, achieving high positional accuracy while maintaining ease of manufacture through modular assembly processes. The levelling surface provides a standardized platform that simplifies the mounting process despite the precision requirements
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 approach enables the creation of an economically manufacturable LED illumination system with high numerical aperture, achieving precise and uniform light distribution for fine details in stereolithography, while maintaining the LEDs' operational efficiency and extending their lifespan.
Implementation Method 1
a levelling surface with high thermal conductivity, using bare dies for improved positional accuracy and thermal management
Implementation Method 2
The lenses may serve to image the light-emitting surfaces of the LEDs onto the surface of the photopolymer resin
Implementation Method 3
an illumination system comprising two-dimensional arrays of LEDs and lenses to provide for selective illumination of the photopolymer resin
Data Source
AI summary
The present invention relates to an illumination system for use in a stereolithography apparatus. The illumination system includes a plurality of light-emitting diodes (LEDs), each LED having at least a first light-emitting surface and a second surface, at least one of the first and the second surface being substantially flat. The illumination further includes a plurality of electrical pathways, selectively connected to the respective LEDs, such that each LED can be individually controlled and a leveling surface. The leveling surface is substantially flat and in leveling contact with the at least one substantially flat surface of each LED, such that a two-dimensional array of LEDs extends in a plane parallel to the leveling surface.