LED Light Source Alignment in Stereolithography
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Solution Overview
Problem
The use of light emitting diodes in stereolithography apparatuses poses challenges due to their short lifespan and the complexity of replacing them without affecting the alignment of the optical axis, leading to inefficiencies and increased maintenance needs.
Innovation Solution
A stereolithography apparatus with a printed circuit board and spatial light modulators, where the light emitting diodes are easily exchangeable and aligned using a releasable locking mechanism, and an alarm system for timely replacement, along with cooling means to prevent damage from heat, ensuring precise alignment and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If light emitting diodes are used in stereolithography apparatus, then energy efficiency is improved, but lifespan is reduced and maintenance complexity increases
Solution Approach 1:
The light emitting diode is divided into separable components: the LED itself and the printed circuit board assembly. This allows the LED to be replaced independently without replacing the entire light source bed or optical system, reducing maintenance complexity despite the reduced lifespan of the LED component.
Solution Approach 2:
The releasable locking mechanism enables operator-performed maintenance without requiring specialized service personnel. The simple lock/release system allows users to replace depleted LEDs themselves, addressing the maintenance burden caused by shortened LED lifespan.
2Productivity
If light emitting diodes are replaced frequently, then continuous operation is maintained, but alignment precision is compromised and service time increases
Solution Approach 1:
The printed circuit board is pre-aligned and locked in a fixed position within the light source bed, establishing precise optical alignment before the LED is installed. This preliminary positioning ensures that when the LED is replaced, alignment precision is maintained without requiring realignment procedures.
Solution Approach 2:
The releasable locking mechanism creates a reproducible positioning system. Each time the printed circuit board is installed, the locking mechanism reproduces the same precise alignment position, ensuring consistent optical axis alignment across multiple LED replacements.
3Manufacturing precision
If light emitting diodes are exchanged individually, then precision alignment is maintained, but operation time is reduced and complexity increases
Solution Approach 1:
Multiple light emitting diodes are combined on a single printed circuit board assembly. This merging allows all LEDs on the board to be replaced simultaneously as one unit, significantly reducing the total time required for maintenance compared to individual replacement, while the locking mechanism ensures the entire assembly maintains precise alignment.
Solution Approach 2:
The printed circuit board serves multiple functions: it provides electrical connections, mechanical support, and precise positioning for multiple LEDs. This multi-functionality allows a single replacement operation to address multiple LEDs, reducing operational time loss.
4Ease of repair
If the light source bed is removed for LED replacement, then complete access is achieved, but device complexity increases and time is lost
Solution Approach 1:
The light emitting diode is extracted from the light source bed assembly by removing only the printed circuit board containing the LED, while leaving the complex light source bed with its optical components in place. This selective extraction provides sufficient access for LED replacement without requiring disassembly of the entire optical system.
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 solution extends the lifespan of the apparatus, simplifies maintenance, and ensures precise alignment and efficient operation by allowing easy replacement of light emitting diodes and monitoring their usage, reducing the need for frequent service checks and improving energy efficiency.
Implementation Method 1
at least one light emitting diode
Implementation Method 2
input optics optically coupled to said spatial light modulators, output optics optically coupled to said spatial light modulators, wherein said input optics and output optics facilitate transmission of light emitted from said light emitting diodes
Implementation Method 3
spatial light modulators enable an establishment of a pattern of the light from said input optics, according to control signals from said control unit
Implementation Method 4
output optics enables focusing of the pattern of light from said spatial light modulators onto an illumination area
Data Source
AI summary
A stereolithography apparatus and an exposure system for a stereolithography apparatus, wherein light emitting diodes are used as light sources. The invention relates to aligning light from the light emitting diode and to the exchange and control the light emitting diodes.