Transparent Fluid Cooling for Light Valves Under High-Intensity Optics
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Solution Overview
Problem
In continuous diode additive manufacturing processes, optically addressed light valves experience significant thermal effects due to excessive optical absorption, leading to overheating and potential non-operation, especially when high-powered light is used to melt metals.
Innovation Solution
A temperature-controlled cooling system for the light valve is implemented, using a cooling fluid with low fluid pressure that is transparent to the high-powered light wavelength, preventing compression of the liquid crystal gap and effectively managing thermal buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-powered light is used to melt metals in continuous diode additive manufacturing, then productivity and manufacturing capability are improved, but thermal effects and optical absorption increase causing overheating and potential non-operation
Solution Approach 1:
A cooling fluid is introduced as an intermediary substance between the light valve and the environment. The fluid circulates through channels in contact with the light valve, absorbing excess heat and preventing overheating while allowing the high-powered light operation to continue
Solution Approach 2:
A hydraulic cooling system is implemented where cooling fluid is pumped through channels formed in contact with the light valve. The fluid flow removes thermal energy from the light valve, enabling continuous operation at high power levels without thermal damage
2Temperature
If cooling fluid is used to manage thermal buildup, then temperature control is improved, but fluid pressure may compress the liquid crystal gap affecting optical performance
Solution Approach 1:
The cooling channels are designed to apply cooling pressure only to specific regions of the light valve that require thermal management, while maintaining uniform pressure distribution to avoid compressing the liquid crystal gap. This localized approach allows effective cooling without compromising optical performance
Solution Approach 2:
The cooling fluid pressure is carefully controlled and optimized to a specific range that is sufficient for thermal management but low enough to prevent compression of the liquid crystal gap. By adjusting and maintaining pressure within this optimal parameter range, both cooling effectiveness and optical performance are preserved
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 cooling system prevents overheating of the light valve, ensuring continuous operation by maintaining a stable temperature and minimizing thermal effects, thus ensuring reliable performance in additive manufacturing processes.
Implementation Method 1
A temperature-controlled cooling system for the light valve is implemented, using a cooling fluid... effectively managing thermal buildup
Implementation Method 2
A temperature-controlled cooling system for the light valve is implemented, using a cooling fluid... ensuring continuous operation by maintaining a stable temperature
Data Source
AI summary
The present disclosure relates to a system and apparatus having an optic and a cooling system for cooling the optic. In one example an optically addressed light valve forms the optic. The cooling system includes first and second windows on opposing surfaces of the optically addressed light valve which constrain a cooling fluid to flow over the opposing surfaces. The fluid pressure outside the optically addressed light valve is low enough that it does not compress a liquid crystal gap of the optically addressed light valve. The cooling fluid is also transparent to a high powered light beam which is projected through the first and second windows, and also through the optically addressed light valve, during an additive manufacturing operation.