Rotated UV LED Clusters for Uniform Illumination
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Solution Overview
Problem
Inkjet printers face challenges in achieving uniform UV illumination across the substrate due to the staggered arrangement of UV LED clusters, leading to reduced illumination at border zones between clusters, and potential power loss from malfunctioning LEDs.
Innovation Solution
The LED illumination module incorporates rotated UV LED clusters with additional LEDs at border zones and diagonal current chains to ensure uniform illumination and redundancy, with a controller to compensate for LED malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If UV LED clusters are arranged in a staggered manner to cover the substrate, then the coverage area is increased, but the illumination uniformity deteriorates due to reduced illumination at border zones between clusters
Solution Approach 1:
The patent applies local quality by adding extra LEDs specifically at the border zones between LED clusters. These border LEDs are strategically positioned to compensate for the illumination deficiency at the edges, creating a non-uniform distribution that results in overall uniformity. The border regions receive additional illumination from both adjacent clusters and the dedicated border LEDs, balancing the light distribution across the entire substrate area.
Solution Approach 2:
The patent employs asymmetry by introducing an additional row of LEDs at the borders that breaks the symmetric staggered pattern. Instead of maintaining identical spacing and arrangement throughout, the border zones feature extra LEDs that create an asymmetric configuration. This asymmetric addition specifically targets the under-illuminated border regions, correcting the uniformity issue while preserving the space-efficient staggered layout.
2Area of stationary object
If multiple LED clusters are used to cover the substrate, then the illumination coverage is improved, but the system reliability deteriorates due to potential power loss from malfunctioning LEDs
Solution Approach 1:
The patent implements beforehand cushioning by incorporating redundant LEDs at the border zones between clusters. These additional border LEDs serve as a buffer or cushion against potential failures. If any LED within a cluster malfunctions, the border LEDs and adjacent cluster LEDs provide compensatory illumination, ensuring that the system maintains sufficient curing power and does not fail completely. This redundancy creates a safety margin that protects against reliability issues.
3Productivity
If staggered LED cluster arrangement is used to reduce gaps, then the coverage efficiency is improved, but the manufacturing complexity increases due to precise positioning requirements
Solution Approach 1:
The patent applies segmentation by dividing the LED illumination system into distinct modules: standard interior clusters with regular patterns and specialized border clusters with additional LEDs. This modular segmentation allows each module to be designed and manufactured independently using standardized processes, then assembled into the complete staggered array. The border clusters act as standardized components that can be precisely positioned during assembly, reducing the overall manufacturing complexity compared to designing the entire staggered pattern as a single custom structure.
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 configuration provides consistent UV radiation coverage, minimizing power loss and ensuring uniform illumination across the substrate, even in the event of LED failures.
Implementation Method 1
an ultraviolet (UV) apparatus for applying UV light to UV photo initiators in the UV curable inks, coatings, or adhesives
Implementation Method 2
UV light to UV photo initiators in the UV curable inks, coatings, or adhesives
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An LED illumination source may include one or a plurality of LED illumination modules (100), each LED illumination module (100) comprising a plurality of LED clusters (1041( 1042,1043... 104n), wherein each LED cluster (1041( 1042,1043... 104n), comprises an LED array which is rotated by an angle of rotation with respect to an axis which is parallel to a predefined direction of sweep (124).