Addressable semiconductor array light source for localized radiation delivery

• US 6,683,421 B1
• Filed: 01/26/2001
• Issued: 01/27/2004
• Est. Priority Date: 01/25/2001
• Status: Expired due to Term

• Current Assignee: Excelitas Canada, Inc.
• Original Assignee: EXFO Photonics Solutions Inc. (11172239 Canada, Inc.)
• Inventors: Hubert, Manfred, Kayser, Roy, Farrell, Jim, Kennedy, John, Ghelman, Eduardo
• Primary Examiner(s): VU, DAVID HUNG
• Application Number:
  US09/769,266
• Time in Patent Office: 1,096 Days
• Field of Search: 315/291, 315/307, 315/149, 362/552, 362/555, 362/553, 362/554, 362/558
• US Class Current: 315/291
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 35/0288 Controlling heating or curing of polymers during moulding, e.g. by measuring temperatures or properties of the polymer and regulating the process controlling or regulating chemical, physical or physico- chemical processes in general B01J19/0006
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: G03F 7/70391 Addressable array sources specially adapted to produce patterns, e.g. addressable LED arrays

Abstract

A photocuring device and a method of photocuring using it. The device includes a housing and a light emitting semiconductor array mounted to the housing, capable of emitting light energy having a light output wavelength suitable for initiating a photoreaction. The device also has a power source for providing power to energize the array to emit light energy and a controller coupled to the power source for varying the power provided by the power source to the array.

Claims

1. A light curing device comprising:

(a) a housing;

(b) a light emitting semiconductor array mounted to the housing, capable of emitting light energy having a light output wavelength suitable for initiating a photoreaction;

(c) a power source for providing power to energize the array to emit light energy;

(d) a controller coupled to the power source for varying the power provided by the power source to the array;

(e) wherein the array comprises a plurality of light emitting semiconductors; and

(f) wherein the plurality of semiconductors is grouped into a plurality of groups.

2. The light curing device as claimed in claim 1, wherein the array comprises at least one module of light emitting semiconductors.

3. The light curing device as claimed in claim 2, wherein the at least one module is removably mounted to the housing.

4. The light curing device as claimed in claim 1, wherein the array comprises a plurality of light emitting diodes.

5. The light curing device as claimed in claim 1, wherein the semiconductor array comprises at least one laser diode.

6. The light curing device as claimed in claim 1, wherein the array comprises a plurality of laser diodes.

7. The light curing device as claimed in claim 1, wherein the array comprises at least one reflector positioned proximate at least one light emitting semiconductor to reflect a sidewall emission of light energy from said light emitting semiconductor.

8. The light curing device as claimed in claim 1, wherein the controller also comprises control data interface means for inputting data correlated to a desired power level, and wherein the controller adjusts the power provided by the power source to the semiconductor array to approximate the desired power level.

9. The light curing device as claimed in claim 1, wherein the controller also comprises control data interface means for inputting data correlated to curing parameters, and wherein the controller adjusts the power provided by the power source to the semiconductor array in accordance with the curing parameters.

10. The light curing device as claimed in claim 1, wherein every semiconductor in a group emits light energy having substantially the same peak light output wavelength as every other semiconductor in said group.

11. The light curing device as claimed in claim 10, wherein every semiconductor in a group emits light energy having a substantially different peak light output wavelength than the peak light output wavelength of light emitted by the semiconductors in every other group.

12. The light curing device as claimed in claim 1, wherein the semiconductors in a group are positioned in the array to form a shape approximating the surface area of a portion of a workpiece to be cured.

13. The light curing device as claimed in claim 1, wherein the controller is adapted to vary the level of power supplied to at least one group.

14. The light curing device as claimed in claim 1, wherein the controller is adapted to separately vary the level of power supplied to at least one group over time.

15. The light curing device as claimed in claim 1, wherein the controller also comprises control data interface means for inputting data correlated to a desired power level for at least one group, and wherein the controller adjusts the power provided by the power source to each said at least one group of semiconductors to approximate the desired power level for that group.

16. The light curing device as claimed in claim 1, wherein the housing comprises a main body housing and an array housing, and wherein the array is mounted to the array housing.

17. The light curing device as claimed in claim 1, further comprising a cooling system for cooling the array, wherein the cooling system is operationally coupled to the power source.

18. The light curing device as claimed in claim 17, wherein the controller is adapted to vary the power supplied to the cooling system.

19. The light curing device as claimed in claim 17, wherein the cooling system comprises at least one selected from the following set of:

liquid cooled heat sink, fan, thermoelectric cooler, cold plate and heat exchanger.

20. The light curing device as claimed in claim 1, further comprising at least one photo sensor operatively coupled to the controller, wherein the photo sensor is adapted to detect the energy level of light emitted by the array.

21. The light curing device as claimed in claim 20, further comprising an output window positioned above the array, and wherein the output window comprises a transparent material such that a substantial portion of the light emitted by the array passes through the output window.

22. The light curing device as claimed in claim 21, wherein the transparent material is selected such that some of the light emitted by the array is internally reflected within the output window.

23. The light curing device as claimed in claim 22, wherein the photo sensor is positioned proximate the output window such that the photo sensor detects the energy level of the light which is internally reflected within the output window.

24. The light curing device as claimed in claim 20, wherein the photo sensor comprises at least one fiber optic cable positioned within the array and adapted to receive some light energy emitted by the array.

25. The light curing device as claimed in claim 20, wherein the photo sensor comprises at least one light emitting semiconductor which is not energized to emit light energy, wherein the power source is adapted to detect current flow generated by said at least one light emitting semiconductor when the array is energized to emit light energy.

26. The use of the light curing device as claimed in claim 1 to photocure photoreactive materials.

27. The apparatus as claimed in claim 1, wherein the array is configured in shape.

28. The apparatus as claimed in claim 1, wherein the array is configured in a two dimensional shape approximating the shape of a portion of a workpiece to be cured.

29. The apparatus as claimed in claim 28, wherein the array is configured in a three dimensional shape approximating the surface area of a portion of a workpiece to be cured.

30. The apparatus as claimed in claim 1, wherein the array is configured to emit light energy having a broad bandwidth.

31. A light curing device comprising:

(a) a housing;

(b) a light emitting semiconductor array mounted to the housing, capable of emitting light energy having a light output wavelength suitable for initiating a photoreaction;

(c) a power source for providing power to energize the array to emit light energy;

(d) a controller coupled to the power source for varying the power provided by the power source to the array;

(e) wherein the array comprises a plurality of light emitting semiconductors; and

(f) wherein at least one semiconductor is addressable, and wherein the controller is adapted to vary the level of power supplied to said at least one addressable semiconductor.

32. The method of photocuring a photoreactive product, comprising the steps of:

(a) providing a light curing device comprising a plurality of semiconductors capable of emitting light energy suitable for initiating a photoreaction;

(b) positioning a photoreactive product proximate the light curing device; and

(c) selecting a plurality of semiconductors; and

(d) causing the selected plurality of semiconductors to emit light energy suitable for initiating a photoreaction onto the product.

33. The method as claimed in claim 32, wherein step (d) comprises sensing the energy level of the emitted light energy.

34. The method as claimed in claim 33, wherein steps (c) and (d) are repeated with a different selected plurality of addressable semiconductors.