Light emitting diode print head
First Claim
1. A light emitting diode print head comprising:
- an aluminum alloy substrate;
a plurality of flat stainless steel tiles extending in a row on the substrate, each of said tiles including a plurality of light emitting diodes on a face of each of said tiles opposite to the face of the tile which is adjacent to the substrate and having a coefficient of thermal expansion different from a coefficient of thermal expansion of the aluminum substrate and closer to a coefficient of thermal expansion of the light emitting diodes; and
a stainless steel thermal compensation layer having a coefficient of thermal expansion similar to the coefficient of thermal expansion of each of the tiles, the thermal compensation layer being adhesively bonded between the substrate and the tiles by a compliant pressure sensitive adhesive layer between the thermal compensation layer and the substrate, and a compliant adhesive layer between the thermal compensation layer and the tiles.
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0 Petitions
Accused Products
Abstract
A light emitting diode print head has an aluminum substrate or mother plate. A plurality of stainless steel tiles are assembled in a row on the substrate. Each of the tiles has a row of dice, each of which has a row of light emitting diodes. The tiles are assembled so that the LEDs are in a row extending across the print head with the adjacent LEDs at the edges of each of tile being a short distance apart. Compensation for differences in coefficient of thermal expansion between the tiles and substrate is provided by a pair of stainless steel strips adhesively bonded between the tiles and substrate. Each strip is bonded along an edge of the row of tiles away from the row of LEDs by a compliant adhesive. A thermally conductive compliant adhesive is provided between the tiles and substrate beneath the LEDs for heat transfer. The stainless steel strips serve as compensation for the difference in coefficient of thermal expansion between the tiles and substrate. There is a yield increase in print heads of at least 10% without any significant cost increase.
51 Citations
19 Claims
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1. A light emitting diode print head comprising:
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an aluminum alloy substrate; a plurality of flat stainless steel tiles extending in a row on the substrate, each of said tiles including a plurality of light emitting diodes on a face of each of said tiles opposite to the face of the tile which is adjacent to the substrate and having a coefficient of thermal expansion different from a coefficient of thermal expansion of the aluminum substrate and closer to a coefficient of thermal expansion of the light emitting diodes; and a stainless steel thermal compensation layer having a coefficient of thermal expansion similar to the coefficient of thermal expansion of each of the tiles, the thermal compensation layer being adhesively bonded between the substrate and the tiles by a compliant pressure sensitive adhesive layer between the thermal compensation layer and the substrate, and a compliant adhesive layer between the thermal compensation layer and the tiles. - View Dependent Claims (2, 3, 4, 5)
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6. A light emitting diode print head comprising:
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an elongated metal substrate; a row of metal tiles along the metal substrate, the metal tiles each having a coefficient of thermal expansion different from a coefficient of thermal expansion of the metal substrate; a row of light emitting diode dice on each of the metal tiles, the row of dice on each of the tiles collectively forming a row of light emitting diode dice extending along the length of the substrate; a pair of metal shims extending along the length of the substrate, each each of the metal shims being between the tiles and the substrate along a portion of the tiles remote from the light emitting diode dice and having a coefficient of thermal expansion similar to the coefficient of thermal expansion of the tiles; means for adhesively bonding the metal shims to the substrate and for adhesively bonding the tiles to the shims; and a layer of compliant adhesive for thermal transfer directly between the substrate and a portion of the tiles opposite the light emitting diode dice. - View Dependent Claims (7, 8)
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9. A light emitting diode print head comprising:
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an elongated aluminum alloy substrate; a row of substantially rectangular stainless steel tiles extending along the length of the aluminum substrate on a front face of the substrate; a row of light emitting diode dice extending across a center portion of a front face of each of the tiles, the row of dice on each of the tiles collectively forming a row of light emitting diode dice extending along the length of the substrate; a pair of stainless steel shims extending along the length of the substrate, each metal shim being between the front face of the substrate and an edge of the tiles remote from the light emitting diode dice; compliant means for adhesively bonding the metal shims to the front face of the substrate; means for adhesively bonding back faces of the tiles to the shims; and a compliant adhesive layer directly between the substrate and a portion of the tiles opposite the light emitting diode dice for transferring heat. - View Dependent Claims (10, 11, 12, 13)
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14. A light emitting diode print head comprising:
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an aluminum alloy substrate; a plurality of stainless steel tiles extending in a row along the substrate; a plurality of light emitting diode dice arranged in a row on each of the tiles, each of said light emitting diode dice having a row of light emitting diodes collectively forming a row of light emitting diodes on the row of tiles with light emitting diodes in the collective row being equal distances apart; a pair of strips of metal, each of the strips extending along a lateral edge of the row of tiles, with a gap between the metal strips underlying the row of light emitting diode dice forming a thermal compensation layer between the substrate and the tiles and having a coefficient of thermal expansion different from a coefficient of thermal expansion of the substrate and closer to a coefficient of thermal expansion of the tiles; a compliant adhesive layer between the thermal compensation layer and the substrate; a compliant adhesive layer between the thermal compensation layer and the tiles; and a layer of compliant adhesive between the tiles and the substrate in the gap. - View Dependent Claims (15, 16, 17)
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18. A light emitting diode print head comprising:
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an elongated metal substrate; a row of metal tiles along the metal substrate, the metal tiles having a coefficient of thermal expansion different from a coefficient of thermal expansion of the metal substrate; a row of light emitting diode dice on each of the metal tiles, the row of dice on each of the tiles collectively forming a row of light emitting diode dice extending along the length of the substrate; a pair of metal shims extending along the length of the substrate, each of the metal shims being between the tiles and the substrate along a portion of the tiles remote from the light emitting diode dice and having a coefficient of thermal expansion intermediate between the coefficient of thermal expansion of the tiles and the coefficient of thermal expansion of the substrate; a compliant pressure sensitive adhesive layer for adhesively bonding the metal shims to the substrate; a compliant adhesive layer for adhesively bonding the tiles to the shims; and a compliant adhesive layer between the tiles and the substrate beneath the row of light emitting diode dice in a gap between the shims for thermal transfer directly between the substrate and a portion of the tiles opposite the light emitting diode dice. - View Dependent Claims (19)
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Specification