LED modifying apparatus and method

• US 20050116179A1
• Filed: 06/16/2004
• Published: 06/02/2005
• Est. Priority Date: 12/02/2003
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Hofeldt, Dave L., Phillips, David L., Lai, Jack W., Benson, Peter T., Aguirre, Francis M., Craton, Michele A.
• Granted Patent: US 7,189,983 B2
• Time in Patent Office: Days
• US Class Current: 250/492.100
• CPC Class Codes: A61C 19/003 Apparatus for curing resins by radiation
• CPC Class Codes: A61C 19/004 Hand-held apparatus, e.g. guns
• CPC Class Codes: F21K 9/69 Details of refractors forming part of the light source
• CPC Class Codes: F21V 29/80 with pins or wires
• CPC Class Codes: G02B 6/06 the relative position of the fibres being the same at both ends, e.g. for transporting images
• CPC Class Codes: G02B 6/4201 Packages, e.g. shape, construction, internal or external details
• CPC Class Codes: G02B 6/4206 Optical features G02B6/4207, G02B6/421 take precedence
• CPC Class Codes: G02B 6/423 using guiding surfaces for the alignment
• CPC Class Codes: G02B 6/4231 with intermediate elements, e.g. rods and balls, between the elements
• CPC Class Codes: G02B 6/4249 comprising arrays of active devices and fibres
• CPC Class Codes: G02B 6/4269 with heat sinks or radiation fins
• CPC Class Codes: G02B 6/4298 coupling with non-coherent light sources and/or radiation detectors, e.g. lamps, incandescent bulbs, scintillation chambers

Abstract

A radiation modifying apparatus comprises a plurality of solid state radiation sources to generate radiation that modifies a first material such as by curing or creating alignment through polarization. The solid state radiation sources can be disposed in an array pattern. Optical concentrators, arranged in a corresponding array pattern, receive radiation from corresponding solid state radiation sources. The concentrated radiation is received by a plurality of optical waveguides, also arranged in a corresponding array pattern. Each optical waveguide includes a first end to receive the radiation and a second end to output the radiation. The radiation modifying apparatus can be utilized for continuous substrate, sheet, piece part, spot curing, and/or 3D radiation-cure processes.

Claims

1. An irradiation apparatus, comprising:

a plurality of solid state radiation sources to generate radiation that modifies a first material;

a controller in electrical communication with the solid state radiation sources to selectively and individually activate each of the solid state radiation sources of the plurality;

a plurality of optical concentrators, wherein each concentrator receives radiation from one or more of the plurality of solid state radiation sources;

a plurality of optical waveguides, wherein each of the plurality of optical waveguides includes a first end and a second end, wherein each first end receives radiation from one or more of the plurality of optical concentrators; and

a support structure to stabilize at least a first portion of the second ends of the plurality of optical waveguides.

2. The irradiation apparatus of claim 1, wherein the controller selectively and individually controls the intensity of radiation from each of the solid state radiation sources of the plurality that is activated.

3. The irradiation apparatus of claim 1, wherein the controller causes the solid state radiation sources to produce pulsed radiation.

4. The irradiation apparatus of claim 1, further comprising an optical element placed in the pathway of radiation emanating from the second ends.

5. The irradiation apparatus of claim 1, wherein the controller selectively and individually activates each of the solid state radiation sources to create patterns in the first material.

6. An irradiation system, comprising:

a solid state radiation source, comprising

a plurality of LED dies to generate radiation that is capable of modifying a radiation modifiable chemical formulation;

a controller electrically connected to the plurality of LED dies to selectively and individually activate each of the LED dies of the plurality;

a plurality of optical concentrators, wherein each concentrator receives the radiation from one or more of the LED dies;

a plurality of optical fibers, wherein each of the plurality of optical fibers includes a first end and a second end, wherein each first end receives concentrated radiation from one or more of the plurality of optical concentrators; and

a substrate to support the radiation modifiable chemical formulation.

7. The irradiation system of claim 6, wherein the controller selectively and individually controls the intensity of radiation from each of the LED dies of the plurality that is activated.

8. The irradiation system of claim 6, wherein the controller selectively and individually activates each of the LED dies to create patterns in the radiation modifiable chemical formulation.

9. The irradiation system of claim 6, further comprising an optical element placed in the pathway of the radiation emanating from the second ends.

10. An irradiation apparatus, comprising:

a plurality of solid state radiation sources to generate radiation that modifies a first material;

a controller in electrical communication with the solid state radiation sources to selectively and individually control the intensity of radiation from each of the solid state radiation sources of the plurality;

a plurality of optical concentrators, wherein each concentrator receives radiation from one or more of the plurality of solid state radiation sources;

a plurality of optical waveguides, wherein each of the plurality of optical waveguides includes a first end and a second end, wherein each first end receives radiation from one or more of the plurality of optical concentrators; and

a support structure to stabilize at least a first portion of the second ends of the plurality of optical waveguides.

11. The irradiation apparatus of claim 10, wherein the controller selectively and individually activates each of the solid state radiation sources of the plurality.

12. The irradiation apparatus of claim 10, wherein the controller causes the solid state radiation sources to produce pulsed radiation.

13. The irradiation apparatus of claim 10, wherein the first material is disposed on a non-uniform structure and wherein the controller selectively and individually controls the intensity of radiation from each of the solid state radiation sources to deliver uniform irradiance to the first material in accordance with the non-uniform structure.

14. The irradiation apparatus of claim 10, wherein the first material has a surface with varying transmissibility and wherein the controller selectively and individually controls the intensity of radiation from each of the solid state radiation sources in accordance with the varying transmissibility.

15. An irradiation system, comprising:

a solid state radiation source, comprising

a plurality of LED dies to generate radiation that is capable of modifying a radiation modifiable chemical formulation;

a controller electrically connected to the plurality of LED dies to selectively and individually control the intensity of radiation from each of the LED dies of the plurality;

a plurality of optical concentrators, wherein each concentrator receives the radiation from one or more of the LED dies;

a plurality of optical fibers, wherein each of the plurality of optical fibers includes a first end and a second end, wherein each first end receives concentrated radiation from one or more of the plurality of optical concentrators; and

a substrate to support the radiation modifiable chemical formulation.

16. The irradiation system of claim 15, wherein the controller selectively and individually activates each of the LED dies of the plurality.

17. The irradiation system of claim 15, wherein the controller causes the plurality of LED dies to produce pulsed radiation.

18. The irradiation system of claim 15, wherein the radiation modifiable chemical formulation is disposed on a non-uniform structure and wherein the controller selectively and individually controls the intensity of radiation from each of the LED dies to deliver uniform irradiance to the radiation modifiable chemical formulation in accordance with the non-uniform structure.

19. The irradiation system of claim 15, wherein the radiation modifiable chemical formulation has a surface with varying transmissibility and wherein the controller selectively and individually controls the intensity of radiation from each of the LED dies in accordance with the varying transmissibility.

20. An irradiation apparatus, comprising:

a plurality of solid state radiation sources to generate radiation that modifies a first material;

a plurality of optical concentrators, wherein each concentrator receives radiation from one or more of the plurality of solid state radiation sources;

a plurality of optical waveguides, wherein each of the plurality of optical waveguides includes a first end and a second end, wherein each first end receives radiation from one or more of the plurality of optical concentrators; and

a light valve disposed in the pathway of radiation emanating from one or more of the second ends of the waveguides; and

a support structure to stabilize at least a first portion of the second ends of the plurality of optical waveguides.

21. The irradiation apparatus of claim 20, wherein the light valve is a liquid crystal array.

22. The irradiation apparatus of claim 20, wherein the light valve is a grating light valve.

23. The irradiation apparatus of claim 20, further comprising an optical element placed in the pathway of radiation emanating from the second ends such that the light valve is in a pathway of radiation emanating from the optical element.

24. The irradiation apparatus of claim 23, wherein the optical element focuses the radiation from the one or more second ends of the waveguide onto the light valve.

25. The irradiation apparatus of claim 20, wherein the light valve adjusts the radiation to create a pattern in the radiation modifiable material.

26. The irradiation apparatus of claim 25, wherein the light valve deflects at least a portion of the radiation to create the pattern.

27. The irradiation apparatus of claim 27, further comprising:

a first polarizer placed in the pathway of radiation emanating from the waveguide such that polarized radiation reaches the light valve, wherein the light value rotates the polarization of the radiation;

a second polarizer placed in the pathway of radiation emanating from the light valve, the second polarizer controlling the intensity of the radiation according to the rotation of the polarization.

28. An irradiation system, comprising:

a solid state radiation source, comprising

a plurality of LED dies to generate radiation that is capable of modifying a radiation modifiable chemical formulation;

a plurality of optical concentrators, wherein each concentrator receives the radiation from one or more of the LED dies;

a plurality of optical fibers, wherein each of the plurality of optical fibers includes a first end and a second end, wherein each first end receives concentrated radiation from one or more of the plurality of optical concentrators;

a light valve placed in the pathway of radiation emanating from one or more of the second ends of the waveguide; and

a substrate to support the radiation modifiable chemical formulation.

29. The irradiation system of claim 28, wherein the light valve is a liquid crystal array.

30. The irradiation system of claim 28, wherein the light valve is a grating light valve.

31. The irradiation system of claim 28, wherein the light valve creates a pattern in the radiation modifiable chemical formulation.