Lighting Assembly Baffle for Uniform Irradiance
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Solution Overview
Problem
Additive manufacturing machines face challenges in achieving uniform irradiance and heat distribution when using quartz infrared halogen lamps, particularly for pre-heating and fusing polyamide 12 build material powders, as the densely wound filaments can lead to non-uniform irradiation.
Innovation Solution
A baffle is positioned between the lamp and the target surface, forming an elongated exposure window with a dumbbell-shaped opening to ensure uniform irradiance, and reflectors are used to direct light efficiently, compensating for heat losses and maintaining consistent heating profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a densely wound filament is used in a quartz infrared halogen lamp to achieve desired irradiating power, then the power output is sufficient, but the irradiance becomes non-uniform along the length of the lamp
Solution Approach 1:
A baffle is introduced as an intermediary component between the lamp and the build material powder. The baffle includes a reflective surface that redirects light paths and an opening that selectively transmits light, thereby mediating the non-uniform irradiance from the densely wound filament into a uniform distribution across the work area
Solution Approach 2:
The baffle is designed with non-uniform features: the reflective surface has varying orientations at different locations, and the opening has specific dimensions and positioning. These local variations in the baffle's structure create different light transmission and reflection characteristics at different positions, compensating for the non-uniformity of the lamp's irradiance output
2Manufacturing precision
If the area covered by the opening is made constant along the length of the lamp, then uniform irradiance is achieved, but heat losses along the sides of the work area increase
Solution Approach 1:
The baffle's opening is designed with an asymmetric dumbbell shape rather than a uniform rectangular shape. This asymmetric geometry strategically positions light transmission areas to compensate for heat losses at the ends of the work area, creating higher irradiance at the ends where heat losses occur and maintaining overall uniformity while reducing energy waste
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 solution achieves uniform irradiance and consistent heat delivery across the work area, enhancing the efficiency of the additive manufacturing process by optimizing the power absorption and distribution of the build material powders.
Implementation Method 1
a reflector covering the lamp so that substantially all of the light emitted by the lamp is directed toward the baffle either directly from the lamp or indirectly by the reflector
Implementation Method 2
Light absorbing components in the fusing agent absorb light energy from the fusing lamp
Implementation Method 3
Quartz infrared halogen lamps may be used for both warming and fusing
Implementation Method 4
A more densely wound filament may be used in a lower color temperature quartz infrared halogen lamp to achieve the desired irradiating power
Data Source
AI summary
In one example, a lighting assembly includes a housing to hold an elongated lamp and an elongated device attached to or integral with the housing and configured to, when an lamp is held in the housing, convert light from the lamp having a first irradiance that is non-uniform along a length into light having a second irradiance that is uniform along the length.