Pulsed LED High-Power Light System Thermal Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-power LED lamps used in manufacturing miniature structures generate excessive heat, leading to thermal distortion, overheating, and reduced productivity due to non-actinide energy transfer and broadened energy spectrum, which limits their power output and manufacturing efficiency.
Innovation Solution
A high-power light system comprising a high-power lamp with multiple LEDs that emit pulses of light within a designated wavelength range, a chiller to maintain the lamp below a defined temperature threshold, and a control module to regulate the lamp's operation, restricting activation to periodic pulses and monitoring heat levels to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-power LED lamps are used to maximize light output for curing photoresist, then manufacturing productivity is improved, but excessive heat is generated causing thermal distortion and substrate damage
Solution Approach 1:
The patent applies periodic pulsed operation of LED lamps instead of continuous operation. The control module activates LEDs in periodic pulses with duty cycles ranging from 1% to 50%, allowing the LEDs to generate sufficient light output for curing photoresist while providing cooling intervals that prevent excessive heat accumulation and thermal distortion of the substrate.
2Illumination intensity
If higher current is applied to LEDs to maintain output yield, then light output is maintained, but heat generation increases causing LED overheating and potential damage
Solution Approach 1:
The patent implements periodic pulsing of LED current with controlled duty cycles. During active pulses, LEDs receive sufficient current to produce required light output for curing. During off-periods, LEDs cool down preventing thermal runaway and extending operational lifespan. The control module dynamically adjusts pulse width and frequency to maintain light output while managing thermal load.
Solution Approach 2:
The patent incorporates temperature sensors that continuously monitor LED junction temperature and provide feedback to the control module. Based on this feedback, the control module dynamically adjusts the duty cycle and pulse width to maintain optimal operating temperature, preventing overheating while ensuring sufficient light output for manufacturing productivity.
3Productivity
If continuous operation of high-power LEDs is maintained, then manufacturing efficiency is improved, but heat accumulation broadens and shifts the energy spectrum reducing curing precision
Solution Approach 1:
The patent uses periodic pulsed operation to maintain LED junction temperature within optimal ranges. By controlling duty cycles and pulse frequencies, the system prevents thermal drift that would otherwise broaden and shift the LED emission spectrum. This ensures precise wavelength control matching photoresist absorption characteristics, maintaining curing precision while achieving manufacturing efficiency through optimized pulse parameters.
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 maximizes actinide energy production while minimizing non-actinide energy, reducing thermal damage and maintaining efficient manufacturing productivity by controlling temperature and energy dosage, thus extending LED lifespan and improving product yield.
Implementation Method 1
a chiller in thermal communication with the high-power lamp for maintaining the high-power lamp below a defined temperature threshold
Implementation Method 2
a high-power lamp for producing light within a defined wavelength range... multiple light emitting diodes (LEDs) which selectively emit pulses of light
Implementation Method 3
light of a particular wavelength that, in turn, can be utilized to be selectively absorbed to cure photoresist
Data Source
AI summary
A high-power light system includes a lamp for producing light within a designated wavelength range, a chiller for maintaining the lamp below a defined temperature threshold, and a control module for regulating operation of both the lamp and the chiller. The lamp includes a plurality of light emitting diodes (LEDs) arranged into independently-operable modules. In use, the control module selectively overdrives the LEDs to yield high-power light within the designated wavelength range. To prevent overheating within the lamp, the control module restricts the lamp to a pulse-based operational cycle, whereby each period of LED activation is of limited duration and is immediately followed by a period of deactivation at least three times as long in duration as the period of activation. Additionally, one or more temperature sensors are disposed within the lamp and enable the control module to temporarily suspend LED activation when measured temperature levels exceed the defined threshold.