Solid state light source for photocuring

• US 9,217,561 B2
• Filed: 05/24/2013
• Issued: 12/22/2015
• Est. Priority Date: 06/15/2012
• Status: Active Grant

• Current Assignee: Lumencor, Inc.
• Original Assignee: Lumencor, Inc.
• Inventors: Jaffe, Claudia B., Jaffe, Steven M., Tylinski, George S.
• Primary Examiner(s): NEILS, PEGGY A
• Application Number:
  US13/901,727
• Publication Number:
  US 20130335992A1
• Time in Patent Office: 942 Days
• Field of Search: 362/231, 362/572, 362/573, 433/29, 607/88
• US Class Current: 1/1
• CPC Class Codes: A61C 19/003 Apparatus for curing resins by radiation
• CPC Class Codes: F21V 11/00 Screens not covered by groups F21V1/00, F21V3/00, F21V7/00 or F21V9/00 characterised by cooling arrangements F21V29/502
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F26B 3/28 by radiation, e.g. from the sun
• CPC Class Codes: G02B 2006/4297 having protection means, e.g. protecting humans against accidental exposure to harmful laser radiation
• CPC Class Codes: G02B 27/10 Beam splitting or combining systems polarising systems G02B27/28; mixing and splitting light signals using optical waveguides G02B6/28; beam shaping, e.g. changing the cross-sectional area, by dividing or superposing multiple light beams G02B27/0905
• CPC Class Codes: G02B 27/141 using dichroic mirrors
• CPC Class Codes: G02B 6/0006 Coupling light into the fibre in general G02B6/4298
• CPC Class Codes: G02B 6/0008 the light being emitted at the end of the fibre
• CPC Class Codes: G02B 6/3849 using mechanical protective elements, e.g. caps, hoods, sealing membranes G02B6/3816 takes precedence; provisionally see H01R13/44
• CPC Class Codes: G02B 6/4269 with heat sinks or radiation fins
• CPC Class Codes: G02B 6/4292 the light guide being disconnectable from the opto-electronic element, e.g. mutually self aligning arrangements

Abstract

A compact passively-cooled solid state illumination system is provided as a replacement for conventional arc light, metal halide and Xenon white-light sources for photocuring applications. The solid state illumination system utilizes LED modules to generate high intensity light output suitable for photocuring. The light output is continuous in the visible spectrum from 380 nm to 530 nm and is suitable for photocuring using a wide range of photoinitiators. A touchscreen interface allows programming of spectral output, intensity and duration. Output can be initiated using the touchscreen interface and/or a foot pedal.

Claims

1. A photocuring system comprising:

a housing enclosing a space;

a metal platform having a first substantially planar surface and a second surface;

the metal platform vertically dividing the enclosed space into a first volume defined by the first substantially planar surface and the housing, and a second volume defined by the second surface and the housing;

the metal platform having on the second surface a plurality of vertically oriented fins;

a first light source positioned within said first volume, the first light source having a first solid state light source, a collimator, and a first metal base, wherein the first solid state light source emits light of a first wavelength which is received by the collimator which generates a collimated first light beam;

a second light source positioned within said first volume, the second light source having a second solid state light source, a collimator, and a second metal base, wherein the second solid state light source emits light of a second wavelength which is received by the collimator which generates a collimated second light beam;

a third light source positioned within said first volume, the third light source having a third solid state light source, a collimator, and a third metal base, wherein the third solid state light source emits light of a third wavelength which is received by the collimator which generates a collimated third light beam;

a plurality of dichroic elements positioned in said first volume and mounted to said first substantially planar surface of said metal platform wherein the plurality of dichroic elements combine the collimated first light beam, collimated second light beam, and collimated third light beam into a combined light beam; and

an output optical stage, positioned in said first volume and mounted to said first substantially planar surface of said metal platform, the optical stage including a lumen for receiving a light guide and comprising a plurality of lenses positioned to receive the combined light beam and focus the combined light beam into an output beam of light suitable for illuminating the light guide;

wherein said first metal base is mounted to said first substantially planar surface of said metal platform such that it provides a heat conducting path between said first solid state light source and the metal platform through which heat generated by the first solid state light source is conducted to the metal platform;

wherein said second metal base is mounted to said first substantially planar surface of said metal platform such that it provides a heat conducting path between said second solid state light source and the metal platform through which heat generated by the second solid state light source is conducted to the metal platform;

wherein said third metal base is mounted to said first substantially planar surface of said metal platform such that it provides a heat conducting path between said third solid state light source and the metal platform through which heat generated by the third solid state light source is conducted to the metal platform;

wherein the housing has a top vent into said second volume and a bottom vent into said second volume whereby hot air can escape from the second volume through the top vent and cool air can be drawn into the second volume through the bottom vent to provide air flow through the second volume and between said vertically oriented fins to provide passive convective cooling of the metal platform and wherein the housing substantially seals the first volume to prevent contamination.

2. The photocuring system of claim 1, further comprising:

a control board mounted within the second volume of the housing, the control board provides current to said plurality of light sources; and

a touchscreen control device external to said housing;

wherein the touchscreen control device is coupled to said control board and configured to control operation of said first light source, second light source and third light source.

3. The photocuring system of claim 2, wherein said output optical stage, includes a spring-loaded mechanical flap within said housing that automatically obstructs said lumen of the output optical stage in the absence of a light guide.

4. The photocuring system of claim 3, in combination with a light guide coupled to the output optical stage through an aperture in said housing, the light guide transmits the output beam of light from the photocuring system.

5. The photocuring system of claim 1, further comprising a control board mounted within the second volume of the housing, the control board provides current to said first solid state light source, second solid state light source, and third solid state light source.

6. The photocuring system of claim 1, wherein said output beam of light has an intensity of at least 10 W/cm² when used with a 3 mm diameter light guide.

7. The photocuring system of claim 1, wherein said output beam of light has a spectral content which is substantially continuous between 380 nm and 530 nm.

8. A photocuring system comprising:

a housing having a top surface and a bottom surface and enclosing a space;

a metal platform having a first substantially planar surface and a second surface;

the metal platform dividing the enclosed space into a first volume defined by the first substantially planar surface and the housing, and a second volume defined by the second surface and the housing;

the metal platform having on the second surface a plurality of vertically oriented fins;

a first light source positioned within said first volume, the first light source having a first LED module, a collimator, and a first metal base, wherein the first LED module emits violet light which is received by the collimator which generates a collimated violet light beam;

a second light source positioned within said first volume, the second light source having a second LED module, a collimator, and a second metal base, wherein the second LED module emits blue light which is received by the collimator which generates a collimated blue light beam;

a third light source positioned within said first volume, the third light source having a third LED module, a collimator, and a third metal base, wherein the third LED module emits cyan light which is received by the collimator which generates a collimated cyan light beam;

a plurality of dichroic elements positioned in said first volume and mounted to said first substantially planar surface of said metal platform wherein the plurality of dichroic elements combine the collimated violet light beam, collimated blue light beam, and collimated cyan light beam into a combined light beam; and

an output optical stage, positioned in said first volume and mounted to said first substantially planar surface of said metal platform, the optical output stage comprising a lumen for receiving a light guide and a plurality of lenses configured to receive the combined light beam and focus the combined light beam into an output beam of light suitable for transmission into the light guide;

wherein said first metal base is mounted to said first substantially planar surface of said metal platform such that it provides a heat conducting path between said first solid state light source and the metal platform through which heat generated by the first solid state light source is conducted to the metal platform;

wherein said second metal base is mounted to said first substantially planar surface of said metal platform such that it provides a heat conducting path between said second solid state light source and the metal platform through which heat generated by the second solid state light source is conducted to the metal platform;

wherein said third metal base is mounted to said first substantially planar surface of said metal platform such that it provides a heat conducting path between said third solid state light source and the metal platform through which heat generated by the third solid state light source is conducted to the metal platform;

wherein the housing has a top vent through said top surface into said second volume and a bottom vent through said bottom surface into said second volume whereby air can escape from the second volume through the top vent and air can be drawn into the second volume through the bottom vent to provide air flow through the second volume and between said vertically oriented fins to provide passive convective cooling of the metal platform and wherein the housing substantially seals the first volume to prevent contamination.

9. The photocuring system of claim 8, further comprising:

a control board mounted within the second volume of the housing, wherein the control board provides current to said first LED module, second LED module, and third LED module; and

a touchscreen control device external to said housing;

wherein the touchscreen control device is coupled to said control board and configured to control operation of said first LED module, second LED module and third LED module.

10. The photocuring system of claim 8 wherein said output optical stage includes a spring-loaded mechanical flap which automatically obstructs said lumen of the output optical stage unless a light guide is connected to the output optical stage.

11. The photocuring system of claim 8, in combination with a light guide coupled through an aperture in said housing to said output optical stage.

12. The photocuring system of claim 8 comprising:

wherein the output beam is substantially continuous between 380 nm and 530 nm and has an intensity of at least 10 W/cm² when used with a 3 mm diameter light guide.

13. The photocuring system of claim 8 further comprising:

a control board mounted within the second volume of the housing, wherein the control board provides current to said first LED module, second LED module, and third LED module; and

a foot pedal external to said housing but coupled to said control board wherein the foot pedal is configured to control light output by the photocuring system.

14. The photocuring system of claim 8 further comprising:

a control board mounted within the second volume of the housing, wherein the control board provides current to said first LED module, second LED module, and third LED module; and

an electronic sensor in said optical output stage, wherein the electronic sensor is coupled to said control board and operative to turn off said first LED module, second LED module, and third LED module unless a light guide is connected to the optical output stage; and

a mechanical flap which automatically obstruct said lumen of the output optical stage unless a light guide is connected to the optical output stage.