LED Linear Light Machine Vision Thermal Optical Design
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Solution Overview
Problem
High intensity linear lighting systems for machine vision applications face challenges with the rapid degradation of tungsten halogen lamps, leading to increased costs and downtime due to frequent replacements, and existing LED solutions are not as efficient or cost-effective as desired.
Innovation Solution
A linear LED lighting system utilizing an elongated support with regularly spaced LED modules and non-imaging concentrators, coupled with high thermal conductivity circuit boards and aberration-corrected cylindrical optics, providing a compact, reliable, and cost-effective high-intensity line source with improved thermal and optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If tungsten halogen lamps are used in linear lighting systems, then high intensity illumination can be achieved, but the lamp lifespan is short and intensity degrades rapidly
Solution Approach 1:
The patent transitions from tungsten halogen lamp technology to LED technology, fundamentally changing the light generation mechanism. LEDs operate at lower temperatures and have no filament to burn out, resolving the contradiction between achieving high illumination intensity and maintaining long operational lifespan. The LED modules with integrated phosphors convert blue light to broad-spectrum white light, maintaining high intensity while eliminating the rapid degradation inherent in tungsten halogen systems.
2Duration of action of stationary object
If pre-packaged LED solutions are used, then lifespan is improved, but thermal management and optical performance are insufficient
Solution Approach 1:
The patent divides the lighting system into modular LED modules, each containing multiple LED chips mounted on a common substrate with integrated thermal management. This segmentation allows for optimized heat dissipation in each module while maintaining overall system reliability. The modular design also enables better optical control and phasing control across the linear array, improving both thermal performance and optical uniformity compared to pre-packaged solutions.
Solution Approach 2:
The patent introduces specialized heat sink structures and thermal interface materials as intermediaries between the LED chips and the cooling system. These intermediaries efficiently conduct heat away from the LED junctions while maintaining electrical isolation and mechanical stability, thereby improving thermal management and overall system reliability without compromising lifespan benefits.
3Duration of action of stationary object
If conventional LED linear lighting is used, then lifespan is extended, but compactness and cost-effectiveness are not optimized
Solution Approach 1:
The patent combines multiple functions into integrated LED modules: light generation, thermal management, and optical control are merged into single modular units. The LED chips, phosphor materials, heat sink structures, and optical elements are integrated into compact modules that reduce overall system complexity while maintaining long lifespan. This consolidation achieves better cost-effectiveness by reducing the number of separate components and simplifying assembly.
4Illumination intensity
If high intensity illumination is achieved with traditional systems, then machine vision applications are supported, but frequent lamp replacement causes downtime and increased costs
Solution Approach 1:
The patent changes the fundamental light generation parameter from thermal incandescence (tungsten halogen) to electroluminescence (LED), achieving high illumination intensity with vastly improved lifespan. This parameter change eliminates the need for frequent lamp replacements, reducing downtime in machine vision applications while maintaining the required illumination levels for web inspection and quality control.
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 system delivers a highly reliable, compact, and cost-effective high-intensity line source with improved thermal and optical performance, offering extended lifespan and uniformity, surpassing the limitations of traditional tungsten halogen systems and pre-packaged LED solutions.
Implementation Method 1
a linear array of regularly spaced LED modules, each comprising one or more LED emitting areas having a predetermined spectral output that is emitted over a predetermined solid angle
Implementation Method 2
an array of spaced apart non-imaging concentrators optically coupled in one-to-one correspondence with the regularly spaced LED modules, each non-imaging concentrator having entrance and exit apertures and operating to collect radiation emitted by each of the LED modules and to re-emit substantially all of the collected radiation as a diverging beam
Implementation Method 3
an elongated cylindrical lens positioned to receive radiation emerging from the exit apertures and converge it to a bright line of light forward of the apparatus
Implementation Method 4
high thermal conductivity circuit boards
Data Source
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AI summary
The invention herein comprises a linear lighting system which incorporates light emitting diode (LED) light sources with one or more distinct colors including broad band white light. The LED die or die arrays are mounted to a high thermal conductivity circuit board comprising COB technology which can include both the LED die and electronic drive components resulting in a more compact and reliable design with improved thermal and optical performance at lower cost. In conjunction with high efficiency imaging collection optics and aberration corrected cylindrical optics, the output of the LED sources are imaged to a bright line suitable for use in machine vision applications and the like.