Passively Cooled LED Light Engine for Photocuring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current photocuring systems, such as those using QTH, arc lamps, and LEDs, face challenges with heat management, spectral stability, and compatibility with various photoinitiators, leading to inefficient polymerization and high maintenance costs.
Innovation Solution
A compact, passively cooled LED light engine system that provides stable, intense light across a broad spectrum suitable for photocuring, with independently operable LED modules and optimized thermal management to reduce heat output and enhance spectral purity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If QTH or arc lamps are used to provide light for photocuring, then broad emission spectra suitable for initiating polymerization in a broad range of resins is achieved, but substantial thermal management systems are required and lamp lifespan is reduced
Solution Approach 1:
The invention divides the single broad-spectrum lamp into multiple separate LED modules, each emitting at a specific wavelength. This segmentation allows each module to target specific photoinitiators without generating excessive heat, while collectively covering a broad spectral range for universal compatibility.
Solution Approach 2:
The invention changes the fundamental operating parameters from single broad-spectrum high-temperature sources to multiple narrow-band low-temperature LED sources. By operating at lower temperatures and using multiple discrete wavelength sources, the system achieves both spectral versatility and reduced thermal management requirements.
2Adaptability or versatility
If QTH or arc lamps are used to provide light for photocuring, then broad emission spectra suitable for initiating polymerization in a broad range of resins is achieved, but costly replacement parts are required due to reduced lifespan
Solution Approach 1:
The system uses multiple independent LED modules instead of a single lamp. Each module can be independently replaced if needed, and LEDs generally have longer operational lifespans than traditional lamps, reducing maintenance costs and improving system reliability.
3Power
If QTH or arc lamps are used to provide light for photocuring, then sufficient light output is achieved, but significant warm-up periods are required before spectral output is stable
Solution Approach 1:
The invention replaces the thermal-mechanical lamp heating system with solid-state LED modules that achieve full spectral output immediately upon activation. This substitution eliminates the warm-up period entirely while maintaining sufficient light output for photocuring applications.
4Temperature
If LEDs are used to provide light for photocuring, then much less heat is generated relative to arc and QTH lamps, but broad emission spectrum and poor spectral stability remain issues
Solution Approach 1:
By segmenting the light source into multiple LED modules with fixed, narrow emission bands, the system achieves spectral stability within each module. The collective output covers a broad range while maintaining stable, predictable emission characteristics from each individual module.
5Ease of operation
If optics are used to narrow the emission band and focus the light output from LEDs, then directional light is achieved, but loss in power and increase in thermal output occur
Solution Approach 1:
Each LED module is designed with its own optical elements optimized for its specific wavelength and emission pattern. This localized optimization allows each module to deliver light efficiently in the desired direction without significant power loss, and the modules can be positioned to achieve the overall directional illumination pattern.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The LED light engine system offers superior performance and cost-effectiveness by providing consistent, high-intensity light for photocuring, with extended lifespan and reduced maintenance, ensuring uniform polymerization across a wide range of photoinitiators and environments.
Implementation Method 1
The present invention provides a solid state light source for use in photocuring applications
Implementation Method 2
The photoinitiator enters an excited state upon absorption of photons of the correct wavelength inducing the creation of free-radicals. The free-radicals induce curing, hardening, and/or polymerization of monomeric, oligomeric or polymeric resin/adhesive
Implementation Method 3
each metal base providing a heat conducting path between a solid state light source and the metal platform whereby heat generated by the solid state light source is conducted via the base to the platform
Implementation Method 4
the housing is vented to allow air flow through the second volume to provide passive convective cooling of the platform
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 2C
AI summary
A compact passively-cooled solid state illumination system is provided as a replacement for conventional arc light, metal halide and Xenon white-light sources for photocuring applications. The solid state illumination system utilizes LED modules to generate high intensity light output suitable for photocuring. The light output is continuous in the visible spectrum from 380nm to 530nm and is suitable for photocuring using a wide range of photoinitiators. A touchscreen interface allows programming of spectral output, intensity and duration. Output can be initiated using the touchscreen interface and/or a foot pedal.