Solid-state light sources for curing and surface modification

• US 7,401,943 B2
• Filed: 06/07/2005
• Issued: 07/22/2008
• Est. Priority Date: 06/07/2005
• Status: Expired due to Fees

• Current Assignee: Heraeus Noblelight America LLC (Heraeus Holding GMBH)
• Original Assignee: Fusion UV Systems, Inc. (Heraeus Holding GMBH)
• Inventors: Cekic, Miodrag, Geller, Boris, Ruckman, Mark W., Okamitsu, Jeffrey
• Primary Examiner(s): Luebke; Renee S
• Assistant Examiner(s): GIRARDI, VANESSA MARY
• Application Number:
  US11/146,018
• Publication Number:
  US 20060274421A1
• Time in Patent Office: 1,141 Days
• Field of Search: 362/227, 362/237, 362/241, 362/297, 362/247, 362/245, 362/243, 362/271, 362/272
• US Class Current: 362/227
• CPC Class Codes: A61C 13/001 Electrophoresis coating
• CPC Class Codes: A61C 13/0022 Blanks or green, unfinished dental restoration parts
• CPC Class Codes: A61C 19/004 Hand-held apparatus, e.g. guns
• CPC Class Codes: A61L 2/084 Visible light
• CPC Class Codes: A61L 2/10 Ultraviolet radiation
• CPC Class Codes: A61L 2/24 Apparatus using programmed or automatic operation
• CPC Class Codes: B05D 3/067 Curing or cross-linking the coating

Abstract

The systems and methods described herein relate to solid-state light sources capable of generating radiation beams for, but not limited to, the treatment of surfaces, bulk materials, films, and coatings. The solid-state ultraviolet source optically combines the light output of at least two and preferably as many four independently controllable discrete solid-state light emitters to produce a light beam that has a controllable multi-wavelength spectrum over a wide range of wavelengths (i.e. deep UV to near-IR). Specific features of this light source permit changes in the spectral, spatial and temporal distribution of light for use in curing, surface modification and other applications.

Claims

1. A solid state light source comprising:

at least three light emitting arrays, each array comprising solid state light emitters which are mounted so that each emitter emits light away from one side of a surface;

at least three optical mixers, each of the at least three optical mixers being symmetrically positioned with respect to at least one pair of the at least three light emitting arrays, reflecting part of the light emitted from one of the at least one pair of symmetrically positioned arrays and transmitting part of the light emitted from another one of the at least one pair of symmetrically positioned arrays to mix the light from the at least one pair of symmetrically positioned arrays to produce mixed light which irradiates a surface; and

a housing comprising an interior curved reflective surface, the housing containing the at least three light emitting arrays and the at least three optical mixers, and including an opening from which the mixed light is emitted and the interior curved reflective surface reflecting at least part of the light emitted from the one side of the arrays toward the surface.

2. A solid state light source in accordance with claim 1 wherein:

the at least three optical mixers comprise at least one prism.

3. A solid state light source in accordance with claim 1 comprising:

a controller, coupled to at least one of the at least three light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band;

wherein the power level of the light emitted by the at least one power-controlled array in the at least one frequency band is chosen to provide a controlled power level of mixed light to irradiate the surface.

4. A solid state light source in accordance with claim 1 wherein:

the at least three optical mixers are joined together and the housing comprises an inward-facing reflective cylinder with a location at which the at least three optical mixers are joined together being located within the cylinder.

5. A solid state light source in accordance with claim 4 wherein:

the at least three optical mixers comprise at least one partially reflective mirror.

6. A solid state light source in accordance with claim 4 comprising:

a controller, coupled to at least one of the at least three light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band;

wherein the power level of the light emitted by the at least one power-controlled array in the at least one frequency band is chosen to provide a controlled power level of mixed light to irradiate the surface.

7. A solid state light source in accordance with claim 1 wherein:

the at least three optical mixers comprise at least one partially reflective mirror.

8. A solid state light source in accordance with claim 7 wherein:

the at least one partially reflective mirror is approximately 50% reflective.

9. A solid state light source in accordance with claim 1 wherein:

the at least three optical mixers and the at least three light emitting arrays comprise four optical mixers and four light emitting arrays.

10. A solid state light source in accordance with claim 9 comprising:

a controller, coupled to at least one of the four light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band;

wherein the power level of the light emitted by the at least one power-controlled array in the at least one frequency band is chosen to provide a controlled power level of mixed light to irradiate the surface.

11. A solid state light source in accordance with claim 9 wherein:

the four optical mixers are joined together and the housing comprises an inward-facing reflective cylinder with a location at which of the four optical mixers are joined together being located within the cylinder.

12. A solid state light source in accordance with claim 11 wherein:

the four optical mixers comprise at least one partially reflective mirror.

13. A solid state light source in accordance with claim 11 comprising:

a controller, coupled to at least one of the four light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band;

wherein the power level of the light emitted by the at least one power-controlled array in the at least one frequency band is chosen to provide a controlled power level of mixed light to irradiate the surface.

14. A solid state light source in accordance with claim 9 wherein:

the four optical mixers comprise at least one partially reflective mirror.

15. A solid state light source in accordance with claim 14 wherein:

the at least one partially reflective mirror is approximately 50% reflective.

16. A solid state light source in accordance with claim 1 wherein:

the at least three optical mixers and the at least three light emitting arrays comprise six optical mixers and six light emitting arrays.

17. A solid state light source in accordance with claim 16 comprising:

a controller, coupled to at least one of the six light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band;

wherein the power level of the light emitted by the at least one power-controlled array in the at least one frequency band is chosen to provide a controlled power level of mixed light to irradiate the surface.

18. A solid state light source in accordance with claim 16 wherein:

the six optical mixers are joined together and the housing comprises an inward-facing reflective cylinder with a location at which the six optical mixers are joined being located within the cylinder.

19. A solid state light source in accordance with claim 18 wherein:

the six optical mixers comprise at least one partially reflective mirror.

20. A solid state light source in accordance with claim 18 comprising:

a controller, coupled to at least one of the six light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band;

wherein the power level of the light emitted by the at least one power-controlled array in the at least one frequency band is chosen to provide a controlled power level of mixed light to irradiate the surface.

21. A solid state light source in accordance with claim 16 wherein:

the six optical mixers comprise at least one partially reflective mirror.

22. A solid state light source in accordance with claim 21 wherein:

the at least one partially reflective mirror is approximately 50% reflective.

23. A solid state light source comprising:

at least two light emitting arrays, each array comprising solid state light emitters which are mounted so that each emitter emits light away from one side of a surface;

at least one optical mixer, each optical mixer being positioned symmetrically with respect to at least one pair of the arrays, reflecting part of the light emitted from one of the at least one pair of symmetrically positioned arrays and transmitting part of the light emitted from another one of the at least one pair of symmetrically positioned arrays to mix the light from the at least one pair of symmetrically positioned arrays to produce mixed light which irradiates a surface; and

a housing comprising an interior curved reflective surface, the housing containing the at least two light emitting arrays and the at least one optical mixer, and including an opening from which the mixed light is emitted and the interior curved reflective surface reflecting at least part of the light emitted from the one side of the arrays toward the surface;

wherein the at least one optical mixer comprises a partially reflective mirror which is less than 40% reflective.

24. A method of irradiating a target surface with a solid state light source including at least three light emitting arrays, each array comprising solid state light emitters which are mounted so that each emitter emits light away from one side of a surface, at least three optical mixers, each optical mixer being positioned symmetrically with respect to at least one pair of the at least three light emitting arrays, reflecting part of the light emitted from one of the at least one pair of symmetrically positioned arrays and transmitting part of the light emitted from another one of the at least one pair of symmetrically positioned arrays to mix the light from the at least one pair of symmetrically positioned arrays to produce mixed light, a housing comprising an interior curved reflective surface, the housing containing the at least three light emitting arrays and the at least three optical mixers and an opening from which the mixed light is emitted and the interior curved reflective surface reflecting at least part of the light emitted from the one side of the arrays to the target surface, the method comprising:

positioning the target surface to be irradiated with the mixed light emitted from the opening.

25. A method in accordance with claim 24 wherein:

the at least three optical mixers comprise at least one prism.

26. A method in accordance with claim 24 wherein the solid state light source further comprises a controller, coupled to at least one of the at least three light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band, the method further comprising:

controlling the power level of light emitted from the at least one power-controlled array in the at least one frequency band to provide a controlled power level of mixed light to irradiate the target surface.

27. A method in accordance with claim 24 wherein:

the at least three optical mixers and the at least three light emitting arrays comprise four optical mixers and four light emitting arrays.

28. A method in accordance with claim 27 wherein the solid state light source further comprises a controller, coupled to at least one of the four light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band, the method further comprising:

controlling the power level of light emitted from the at least one power-controlled array in the at least one frequency band to provide a controlled power level of mixed light to irradiate the target surface.

29. A method in accordance with claim 27 wherein:

the four optical mixers comprise at least one partially reflective mirror.

30. A method in accordance with claim 29 wherein:

the partially reflective mirror is approximately 50% reflective.

31. A method in accordance with claim 27 wherein:

the four optical mixers are joined together and the housing comprises an inward-facing reflective cylinder with a location at which of the four optical mixers are joined together being located within the cylinder.

32. A method in accordance with claim 31 wherein the solid state light source further comprises a controller, coupled to at least one of the four light emitting arrays, which controls a power level of light emitted the from at least one power-controlled array in at least one frequency band, the method further comprising:

controlling the power level of light emitted from the at least one power-controlled array in the at least one frequency band to provide a controlled power level of mixed light to irradiate the target surface.

33. A method in accordance with claim 31 wherein:

the four optical mixers comprise at least one partially reflective mirror.

34. A method in accordance with claim 24 wherein:

the at least three optical mixers and the at least three light emitting arrays comprise six optical mixers and six light emitting arrays.

35. A method in accordance with claim 34 wherein the solid state light source further comprises a controller, coupled to at least one of the six light emitting arrays, which controls a power level of light emitted from the at least one power-controlled array in at least one frequency band, the method further comprising:

controlling the power level of light emitted from the at least one power-controlled array in the at least one frequency band to provide a controlled power level of mixed light to irradiate the target surface.

36. A method in accordance with claim 34 wherein:

the six optical mixers comprise at least one partially reflective mirror.

37. A method in accordance with claim 36 wherein:

the partially reflective mirror is approximately 50% reflective.

38. A method in accordance with claim 34 wherein:

the six optical mixers are joined together and the housing comprises an inward-facing reflective cylinder with a location at which the six optical mixers are joined being located within the cylinder.

39. A method in accordance with claim 38 wherein the solid state light source further comprises a controller, coupled to at least one of the six light emitting arrays, which controls a power level of light emitted the from at least one power-controlled array in at least one frequency band, the method further comprising:

controlling the power level of light emitted from the at least one power-controlled array in the at least one frequency band to provide a controlled power level of mixed light to irradiate the target surface.

40. A method in accordance with claim 38 wherein:

the six optical mixers comprise at least one partially reflective mirror.

41. A method in accordance with claim 24 wherein:

the at least three optical mixers are joined together and the housing comprises an inward-facing reflective cylinder with a location at which the three optical mixers are joined together being located within the cylinder.

42. A method in accordance with claim 41 wherein the solid state light source further comprises a controller, coupled to at least one of the at least three light emitting arrays, which controls a power level of light emitted the from at least one power-controlled array in at least one frequency band, the method further comprising:

controlling the power level of light emitted from the at least one power-controlled array in the at least one frequency band to provide a controlled power level of mixed light to irradiate the target surface.

43. A method in accordance with claim 41 wherein:

the at least three optical mixers comprise at least one partially reflective mirror.

44. A method in accordance with claim 24 wherein:

the at least three optical mixers comprise at least one partially reflective mirror.

45. A method in accordance with claim 44 wherein:

the partially reflective mirror is approximately 50% reflective.

46. A method of irradiating a target surface with a solid state light source including at least two light emitting arrays, each array comprising solid state light emitters which are mounted so that each emitter emits light away from one side of a surface, at least one optical mixer, each optical mixer being positioned symmetrically with respect to at least one pair of the arrays, reflecting part of the light emitted from one of the at least one pair of symmetrically positioned arrays and transmitting part of the light emitted from another one of the at least one pair of symmetrically positioned arrays to mix the light from the at least one pair of symmetrically positioned arrays to produce mixed light, a housing comprising an interior curved reflective surface, the housing containing the at least two light emitting arrays and the at least one optical mixer and an opening from which the mixed light is emitted and the interior curved reflective surface reflecting at least some of the light emitted from the one side of the arrays to the target surface, the method comprising:

positioning the target surface to be irradiated with the mixed light emitted from the opening;

wherein the at least one optical mixer comprises a partially reflective mirror which is less than 40% reflective.