US20050201097A1 - Extensible linear light emitting diode illumination source - Google Patents
Extensible linear light emitting diode illumination source Download PDFInfo
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- US20050201097A1 US20050201097A1 US11/055,008 US5500805A US2005201097A1 US 20050201097 A1 US20050201097 A1 US 20050201097A1 US 5500805 A US5500805 A US 5500805A US 2005201097 A1 US2005201097 A1 US 2005201097A1
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- Prior art keywords
- inner mounting
- lamps
- mounting base
- light source
- extensible
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
- F21V29/50—Cooling arrangements
- F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S4/00—Lighting devices or systems using a string or strip of light sources
- F21S4/20—Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports
- F21S4/28—Lighting devices or systems using a string or strip of light sources with light sources held by or within elongate supports rigid, e.g. LED bars
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
- F21V29/50—Cooling arrangements
- F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
- F21V29/74—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks with fins or blades
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8806—Specially adapted optical and illumination features
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V15/00—Protecting lighting devices from damage
- F21V15/01—Housings, e.g. material or assembling of housing parts
- F21V15/013—Housings, e.g. material or assembling of housing parts the housing being an extrusion
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V15/00—Protecting lighting devices from damage
- F21V15/01—Housings, e.g. material or assembling of housing parts
- F21V15/015—Devices for covering joints between adjacent lighting devices; End coverings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
- F21W2131/00—Use or application of lighting devices or systems not provided for in codes F21W2102/00-F21W2121/00
- F21W2131/40—Lighting for industrial, commercial, recreational or military use
- F21W2131/403—Lighting for industrial, commercial, recreational or military use for machines
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
- F21Y2115/00—Light-generating elements of semiconductor light sources
- F21Y2115/10—Light-emitting diodes [LED]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S362/00—Illumination
- Y10S362/80—Light emitting diode
Definitions
- This invention relates generally to linear light sources, and more specifically to an assembly of high-intensity light emitting diodes in a linear, modular form such that the illumination line can be extended indefinitely.
- Linear light arrays are desirable for use when an specific long, narrow target area must be illuminated.
- One such use is for illumination of a continuous web in a web manufacturing inspection system.
- a web is any material which is manufactured in a single continuous sheet, such as paper and cloth.
- the web typically passes through a web inspection station that analyzes the web for defects.
- Cameras are positioned along the width of a web, with each camera taking images of a specific portion of the width of the web. Defects in the web, including discolorations, holes and tears, are identified as inconsistences in the images.
- the analysis depends upon consistent lighting of the web. Although the analysis may correct for minor lighting variations, dark spots caused by defective or inconsistent lighting may result in a false identifications of defects.
- LED linear arrays A number of companies manufacture modular LED linear arrays. However, these LED linear arrays often are of a fixed length that are not sufficiently long to illuminate a target width. Linear arrays that are extensible use modules that, when connected together, result in gaps between the modules so that the illumination is not uniform. In addition, the brightness of the existing illumination arrays are limited, and the focus of the light is not controllable. Some product offerings consist of LED circuit cards only, requiring the end user to construct a housing, structural mountings, and cooling provisions. Typical prior art illumination sources do not provide sufficient provisions for heat flow away from the illumination source. In addition, these products do not have power supply distribution provisions, and are not sealed for use in extreme environments.
- an illumination source which is compact, energy-efficient and indefinitely extensible, and which combines the reliability advantages of light emitting diodes (LEDs) with the brightness of conventional lighting for use in direct lighting applications or for backlighting for translucent materials.
- LEDs light emitting diodes
- an illumination source that includes an integral base in contact with the inner mounting base which serves as a heat sink and provides structural support for the illumination source, and which includes channels and cavities for cooling the illumination source and for housing power cables.
- an illumination elements e.g, light emitting diodes
- Another advantage of the present invention is to provide an illumination source that has a power distribution system that provides equal power to each LED of the linear LED array.
- Yet another advantage is to provide an environmentally sealed illumination source having structural supports which act as heat sinks, include cooling channels for forced air and other cooling means, and provide flexible mounting provisions.
- the exemplary embodiment of the present invention is a compact, energy-efficient extensible illumination source that utilizes light emitting diodes (LEDs) to provide the advantages of brightness and high reliability.
- the high reliability of the LEDs provides trouble-free operation over a long hour lifetime.
- the illumination source of the exemplary embodiment includes LED printed wire board segments that may be configured to form a light line of any length. The segments are mounted on a inner mounting base which also serves as a first stage heat sink for the LEDs. Linear mirrors are mounted on the inner mounting base with the LEDs running lengthwise between the mirrors. The mirrors reflect and focus the radiant energy from the LEDs onto the target to produce a uniform linear illumination pattern.
- a window is mounted in the illumination source above the LEDs and mirrors to provide mechanical protection for the LEDs. The window may be used for diffusing or filtering light from the LEDs.
- the exemplary embodiment of the illumination source includes assembled segments of a length which can be practically manufactured, and which include provisions for joining individual assemblies together to make indefinitely extensible linear light sources.
- the mounting base and printed wire boards form an assembled segment with the LEDs mounted in patterns such that when these segments are combined, end to end, the illumination remains uniform over the length of the combined assemblies.
- the assembled segments are mounted on a base and enclosed by brackets to provide an environmental seal as well as structural integrity for the illumination source unit.
- Each assembled segment of the exemplary embodiment is powered individually by cables so as to avoid power distribution problems.
- the high intensity light emitting diodes are secured to the mounting base with heat conducting adhesives.
- the mounting base thus acts as a heat sink member.
- An integral base in contact with the inner mounting base also serves as a heat sink and provides structural support for the illumination source.
- the integral base further includes channels and cavities for cooling the illumination source and for housing power cables.
- the high intensity linear light source may be shaped in other geometries other than a straight line, e.g., circular, by designing the printed circuit board accordingly.
- the light source of alternate embodiments can be lasers or incandescent lamps.
- the circuits controlling the light source can be designed to strobe the light source.
- the extensible linear light emitting diode illumination source of an exemplary embodiment is utilized in web inspection systems.
- the illumination source illuminates the continuously manufactured materials, i.e., “webs”, that are under inspection.
- the web inspection systems utilize cameras which optically inspect the webs for surface and other defects. Identified defect areas are analyzed by the cameras and/or by computers which receive the defect information from the cameras. Typical applications of the web inspection system includes defect detection of metals, non-woven materials, textiles, fabrics, film, paper, plastics and other materials that are manufactured as continuous web sheets.
- the illumination source of the exemplary embodiment provides uniform lighting of the web which enables the cameras and/or computers to accurately inspect the webs.
- FIG. 1 is an exploded top view of an assembly of an extensible linear light emitting diode illumination source of a preferred embodiment of the present invention
- FIG. 2 an exploded bottom view of the assembly of FIG. 1 ;
- FIG. 3 is a isometric view of an assembled extensible linear light emitting diode illumination source
- FIG. 4 is a isometric view of a mirrored window support of a preferred embodiment of the present invention.
- FIG. 5 is an side view of the mirrored window support illustrating an angle of the mirror surface
- FIG. 6 is a isometric view of an inner Printed Wire Board (PWB) mounting base of an extensible linear light emitting diode illumination source of the present invention
- FIG. 7 is a cross sectional view of the inner PWB mounting base of FIGS. 6 and 9 ;
- FIG. 8 is a drawing of a top layer of a left PWB of an embodiment of the present invention.
- FIG. 9 is a top view of an inner mounting base of a preferred embodiment.
- FIG. 10 is a drawing of a top layer of a right PWB of the present invention.
- FIG. 11 is a drawing of a web inspection system utilizing the extensible linear light emitting diode illumination source of a preferred embodiment.
- FIG. 12 is a schematic diagram of the circuit of a preferred embodiment of the invention.
- FIG. 1 illustrates an exploded view of an assembly of an extensible linear light emitting diode illumination source 2 of a preferred embodiment of the present invention.
- the illumination source 2 includes an inner printed wire board (PWB) mounting base 10 attached to a base 28 .
- PWB printed wire board
- Right and left mirrored window supports 18 , 20 are mounted to a top surface 32 of the PWB mounting base 10 .
- a window 24 is mounted to top surfaces 34 of the window supports 18 , 20 .
- the PWB mounting base 10 , the mirrored window supports 18 , 20 , and the window 24 are enclosed by brackets 22 and end caps 26 .
- the brackets 22 , end caps 26 , base 28 and window 24 create an environmentally sealed assembly 2 .
- FIG. 3 illustrates an assembled extensible linear LED illumination source 2 of a preferred embodiment.
- the illumination source 2 includes light emitting diodes (LEDs) 16 , which are positioned along an entire length of the inner PWB mounting base 10 .
- the PWB mounting base 10 includes left and right troughs 60 , 62 for accepting and securing the right and left PWB segments 12 , 14 .
- One of the cathode or anode leads of each LED is mounted on a right LED printed wire board (PWB) segment 12 , and the other of the cathode or anode leads of each LED are mounted on a left LED PWB segment 14 .
- the illumination source 2 in alternate embodiments utilizes incandescent light, lasers, or other illumination sources in place of the LEDs 16 .
- Each PWB segment 12 , 14 may be of a standardized size that has lead pads spaced evenly along the entire length of the segment. In other embodiments of the invention, the lead pads may be configured in other patterns to produce light patterns that are required by specific applications of the illumination source 2 .
- FIGS. 8 and 10 illustrate left and right PWB segments 12 , 14 of a preferred embodiment with lead pads 70 , 72 , 74 , 76 , 78 .
- the distance “d” between each lead pad 70 , 72 is constant.
- a distance between the first lead pad 74 and the leading edge of the PWB 12 , 14 , and the last lead pad 76 and the trailing edge of the PWB 12 , 14 joined together equal the constant distance “d”.
- the illumination source 2 is extensible by joining right and left segments 12 , 14 end to end.
- the resulting illumination source 2 produces a uniform illumination, i.e., without illumination gaps, along its entire length.
- All linear components can be manufactured to be of a particular length corresponding to the total number of end to end PWB segments 12 , 14 required for a specific application of the illumination source 2 .
- only the printed wiring boards 12 , 14 are manufactured and assembled in short 20 inch (50.8 cm) segments.
- Continuous length linear components, as described above, provide for mechanical integrity of the resulting illumination source assembly 2 .
- a grouping of assembled components can create an assembled segment that is held together by brackets 24 and/or a base 30 of the required application length, as long as the grouping of assembled components maintain mechanical integrity and an environmental seal.
- the LED printed wire boards 12 , 14 are securely fastened to the inner mounting base 10 which provides a heat sink path for dissipating heat generated by the LEDs 16 .
- the right and left PWB segments 12 , 14 are positioned such that the LEDs 16 straddle a center ridge 64 of the mounting base 10 .
- the center ridge 64 of a preferred embodiment acts as a continuous structural support member and efficient heat sink for the LEDs 16 .
- the LEDs 16 are placed in intimate contact with the center ridge 64 of the inner mounting base 10 .
- the LEDs 16 are cemented to the center ridge 64 using conductive cement to increase rigidity of the LEDs as well as to provide maximum heat transfer of the heat generated by the individual LEDs to the inner mounting base 10 .
- the inner PWB mounting base 10 is in intimate contact with an outer support structure and base 28 which provides a further path for heat transfer.
- a base 28 of a preferred embodiment is extruded aluminum for maximum heat dissipation.
- Linear cavities 36 in the base 28 provide for the circulation of cooling fluid as necessary.
- Fans, filters and electrical junction boxes 130 , 134 can be attached at each terminus of the base 28 to force cooling air through the linear cavities 36 , and/or the cable conduits 38 in the base 28 .
- Mounting channels 30 are utilized for mounting the entire assembly 2 to a supporting structure 102 , as illustrated in FIG. 11 .
- the cable conduits 38 are used for running electrical and power supply cables to each of the PWB segments 12 , 14 .
- FIG. 2 illustrates an exploded bottom view of the extensible linear light emitting diode illumination source 2 of FIG. 1 .
- the illumination source may be mounted above or in front of a target to provide top or front lighting, or may be mounted below or behind the target to provide backlighting.
- the lighting configuration and type of LED utilized depends upon the application of the illumination source.
- the material and type of defects to be detected dictates the lighting configuration, including the configurations of backlighting, front diffuse lighting, front specular lighting, dark field lighting, and oblique lighting.
- the bottom surface of the inner PWB mounting base 10 includes an electrical inset 40 that is aligned with a bore or hole 39 in the base 28 .
- a terminal block slot 42 is recessed within the electrical inset 40 for housing a terminal block 44 .
- the terminal block 44 connects power supply wiring to the PWB segment 12 , 14 via feed thru slots 46 , as shown in FIGS. 7 and 9 .
- each LED illumination segment 12 , 14 has is own power supply connection which allows the LED illumination source 2 to be extended indefinitely without undue power variations between LED illumination segments 12 , 14 .
- the light emitting diodes of a preferred embodiment are red LEDs having a light output of 75,000 Lux. Red LEDs provide maximum illumination while providing a long lifetime, e.g., 100,000 hours.
- An illumination source of a preferred embodiment of the invention requires a 17V DC power source, at 3.5 amps per PWB segment 12 , 14 .
- other color wavelength LEDs, or other radiant sources of any wavelength colors may be utilized if the application so requires.
- the use of LEDs in the illumination source provides illumination uniformity within 10% or better along the entire length of the illuminated target.
- the use of LEDs 16 in conjunction with the window 24 and mirror 50 as described further below, provides a highly controllable and directed light output.
- the window 24 of a preferred embodiment, as shown in FIGS. 1 and 2 provides for mechanical protection for the LEDs 16 .
- the type of window 24 utilized in the illumination source 2 may vary according to the intended use of the illumination source 2 .
- a translucent window 24 may be used as a diffuser in situations where diffused illumination is required.
- a clear window 24 may be used for non-diffuse applications.
- a specific color window 24 may be utilized when filtered emissions are appropriate.
- Other windows 24 may utilize lenslets, or continuous cylindrical or other shaped lenses, to focus the light from the illumination source, e.g., the LEDs 16 .
- FIGS. 1 and 4 illustrate mirrored window supports 18 , 20 of a preferred embodiment.
- the mirror-finished surface 50 of the window support 18 , 20 serves to reflect radiant energy from the individual LEDs 16 in such a manner that a maximum amount of radiant energy is directed away from the LED illumination source 2 and towards the intended target such as a web 108 , as shown in FIG. 11 .
- the LEDs 16 are centered between the right mirrored window support 18 and the left mirrored window support 20 .
- the mirrors 50 span the entire length of the LED illumination source 2 to provide a continuous, uniform, linear illumination.
- FIG. 5 is an end view of the mirrored window support 18 , 20 .
- the mirrored surface 50 is angled with respect to the plane of the PWB segments 12 , 14 on which the mirrored window supports 18 , 20 are anchored.
- the mirrored surface 50 outwardly reflects the illumination produced by the LEDs 16 .
- the inside angle ⁇ of the bracket is approximately 80 degrees, to optimize the illumination intensity since LEDs typically emit a wide angle of illumination. In other embodiments, the angle is varied depending upon the lighting conditions necessary for the specific lighting requirements of the illumination source 2 .
- FIGS. 8 and 10 illustrate the top layers of the left and right printed wiring boards segments 14 , 12 of an embodiment of the invention.
- the left and right printed wiring board segments 14 , 12 are utilized to attach the anode and cathode wiring leads of the individual LEDs 16 .
- the printed wiring board circuitry/traces are arranged in a parallel series configuration so that the failure of a single component, e.g., an LED 16 , does not result in the loss of significant radiated illumination.
- the bottom layers of the PWB segments 12 , 14 include traces which connect groups of lead pads to create a series connection.
- the cathodes of ten (10) LEDs of group A are connected in parallel on the right PWB 12
- the anodes of these LEDs are connected in series to group B on the left PWB 14 .
- the parallel series continues until the end of the PWD segments 12 , 14 , when the anodes of the LEDs of group F are connected to a power return.
- This configuration results in ten (10) parallel LED paths of six (6) LEDs each.
- an LED 16 of a series fails resulting in the failure of the other five LEDs of the series, then the surrounding LEDs of the other series will provide sufficiently uniform illumination along the length of the illumination line.
- FIG. 12 illustrates the circuit realized by the right and left PWB segments 12 , 14 of FIGS. 8 and 10 .
- Terminal block 44 includes a power line connected to the cathodes 150 of the ten LEDs of group A. Six LEDs are connected in ten (10) series branches 154 . The anodes of the final LEDs in the series 154 branches are connected to the power return of the terminal block 44 .
- FIG. 11 illustrates a high performance, web inspection system 100 .
- the system 100 utilizes smart linescan cameras 110 which optically inspect continuous materials 108 , i.e., “webs”, for surface defects.
- Typical applications of the web inspection system 100 includes defect detection of metals, non-woven materials, textiles, fabrics, film, paper, plastics and other materials that are manufactured as continuous web sheets.
- the system 100 employs digital filter processing, adaptive background subtraction and advanced software algorithms to detect very small changes in surface properties.
- the web inspection system 100 includes an illumination source 2 of the preferred embodiment which directs light upward 106 towards the web 108 .
- FIG. 11 illustrates a backlit web 108 .
- the illumination source 2 may be position above the web 108 for top lighting.
- the illumination source 2 consisting of a number of PWB segments 12 , 14 , is mounted on a structural support member 102 by means of the channels 30 of the base 28 , as described above.
- a structural support stand 104 supports both the bank of cameras 110 and the illumination source 102 .
- the cameras 110 which are synchronized by an encoder 116 and synchronization signal 132 , output defect results to a computer 130 by means of an ethernet hub 112 .
- Power supplies 130 provide power to the cameras 110 and the illumination source 2 .
- Cooling equipment 134 provides cooling to the illumination source 2 .
- the computer 118 controls all elements of the inspection system 100 , including the cameras 110 , the illumination source 2 , the power supply 130 , and the cooling equipment 134 .
- the inspection system 100 is also connected via a network to additional equipment such as a remote monitor 124 and a modem 128 that connects to, e.g., the Internet.
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Abstract
A compact, energy-efficient extensible illumination source combines the reliability advantages of light emitting diodes (LEDs) with the brightness of conventional lighting. High reliability of the LEDs provides trouble-free operation over a long hour lifetime. This high-output light source can be used in direct lighting applications or for backlighting for translucent materials. The illumination source includes LED printed wire board segments that may be configured to form a light line of any length. The segments are mounted on a inner mounting base which also serves as a first stage heat sink for the LEDs. The illumination source includes a linear mirror for reflecting radiant energy away from the LEDs to produce a uniform linear illumination pattern. A window provides mechanical protection for the LEDs and may be used for diffusing or filtering light from the LEDs. An integral base in contact with the inner mounting base also serves as a heat sink and provides structural support for the illumination source. The integral base further includes channels and cavities for cooling the illumination source and for housing power cables.
Description
- This application claims the benefit of priority under 35 U.S.C. 119(e) to provisional U.S. Patent Application No. 60/366,066, filed Mar. 18, 2002 which is incorporated herein by reference in its entirety.
- This invention relates generally to linear light sources, and more specifically to an assembly of high-intensity light emitting diodes in a linear, modular form such that the illumination line can be extended indefinitely.
- Linear light arrays are desirable for use when an specific long, narrow target area must be illuminated. One such use is for illumination of a continuous web in a web manufacturing inspection system. A web is any material which is manufactured in a single continuous sheet, such as paper and cloth. The web typically passes through a web inspection station that analyzes the web for defects. Cameras are positioned along the width of a web, with each camera taking images of a specific portion of the width of the web. Defects in the web, including discolorations, holes and tears, are identified as inconsistences in the images. Thus, the analysis depends upon consistent lighting of the web. Although the analysis may correct for minor lighting variations, dark spots caused by defective or inconsistent lighting may result in a false identifications of defects.
- A number of companies manufacture modular LED linear arrays. However, these LED linear arrays often are of a fixed length that are not sufficiently long to illuminate a target width. Linear arrays that are extensible use modules that, when connected together, result in gaps between the modules so that the illumination is not uniform. In addition, the brightness of the existing illumination arrays are limited, and the focus of the light is not controllable. Some product offerings consist of LED circuit cards only, requiring the end user to construct a housing, structural mountings, and cooling provisions. Typical prior art illumination sources do not provide sufficient provisions for heat flow away from the illumination source. In addition, these products do not have power supply distribution provisions, and are not sealed for use in extreme environments.
- Therefore, a need exists for an illumination source which is compact, energy-efficient and indefinitely extensible, and which combines the reliability advantages of light emitting diodes (LEDs) with the brightness of conventional lighting for use in direct lighting applications or for backlighting for translucent materials. A need exists for an illumination source that includes LED printed wire board segments that are mountable on an inner mounting base, wherein the LED printed wire board segments are configured to form a uniform illumination line of any length. A further need exists of an illumination source that includes an integral base in contact with the inner mounting base which serves as a heat sink and provides structural support for the illumination source, and which includes channels and cavities for cooling the illumination source and for housing power cables.
- It is an advantage of the present invention to provide an illumination source that utilizes an illumination elements, e.g, light emitting diodes, to provide maximum brightness, long life, and diffuse or focused light of various wavelengths.
- It is a further advantage to provide an illumination source that is extensible to any length while providing uniformity of illumination.
- If is another advantage to provide an illumination source that individually groups LEDs to avoid catastrophic failure of the entire linear LED array.
- Another advantage of the present invention is to provide an illumination source that has a power distribution system that provides equal power to each LED of the linear LED array.
- Yet another advantage is to provide an environmentally sealed illumination source having structural supports which act as heat sinks, include cooling channels for forced air and other cooling means, and provide flexible mounting provisions.
- The exemplary embodiment of the present invention is a compact, energy-efficient extensible illumination source that utilizes light emitting diodes (LEDs) to provide the advantages of brightness and high reliability. The high reliability of the LEDs provides trouble-free operation over a long hour lifetime. The illumination source of the exemplary embodiment includes LED printed wire board segments that may be configured to form a light line of any length. The segments are mounted on a inner mounting base which also serves as a first stage heat sink for the LEDs. Linear mirrors are mounted on the inner mounting base with the LEDs running lengthwise between the mirrors. The mirrors reflect and focus the radiant energy from the LEDs onto the target to produce a uniform linear illumination pattern. A window is mounted in the illumination source above the LEDs and mirrors to provide mechanical protection for the LEDs. The window may be used for diffusing or filtering light from the LEDs.
- Many applications require continuous, high intensity linear light sources of indefinite length. The exemplary embodiment of the illumination source includes assembled segments of a length which can be practically manufactured, and which include provisions for joining individual assemblies together to make indefinitely extensible linear light sources. In one embodiment of the invention, the mounting base and printed wire boards form an assembled segment with the LEDs mounted in patterns such that when these segments are combined, end to end, the illumination remains uniform over the length of the combined assemblies. The assembled segments are mounted on a base and enclosed by brackets to provide an environmental seal as well as structural integrity for the illumination source unit. Each assembled segment of the exemplary embodiment is powered individually by cables so as to avoid power distribution problems.
- In the exemplary embodiment of the present invention, provisions are made to carry away the heat generated by the LEDs to surrounding structures. For example, the high intensity light emitting diodes (LEDs) are secured to the mounting base with heat conducting adhesives. The mounting base thus acts as a heat sink member. An integral base in contact with the inner mounting base also serves as a heat sink and provides structural support for the illumination source. The integral base further includes channels and cavities for cooling the illumination source and for housing power cables.
- In other embodiments of the invention, the high intensity linear light source may be shaped in other geometries other than a straight line, e.g., circular, by designing the printed circuit board accordingly. The light source of alternate embodiments can be lasers or incandescent lamps. In addition, the circuits controlling the light source can be designed to strobe the light source.
- The extensible linear light emitting diode illumination source of an exemplary embodiment is utilized in web inspection systems. The illumination source illuminates the continuously manufactured materials, i.e., “webs”, that are under inspection. The web inspection systems utilize cameras which optically inspect the webs for surface and other defects. Identified defect areas are analyzed by the cameras and/or by computers which receive the defect information from the cameras. Typical applications of the web inspection system includes defect detection of metals, non-woven materials, textiles, fabrics, film, paper, plastics and other materials that are manufactured as continuous web sheets. The illumination source of the exemplary embodiment provides uniform lighting of the web which enables the cameras and/or computers to accurately inspect the webs.
- The present invention will be better understood from the accompanying drawings in which:
-
FIG. 1 is an exploded top view of an assembly of an extensible linear light emitting diode illumination source of a preferred embodiment of the present invention; -
FIG. 2 an exploded bottom view of the assembly ofFIG. 1 ; -
FIG. 3 is a isometric view of an assembled extensible linear light emitting diode illumination source; -
FIG. 4 is a isometric view of a mirrored window support of a preferred embodiment of the present invention; -
FIG. 5 is an side view of the mirrored window support illustrating an angle of the mirror surface; -
FIG. 6 is a isometric view of an inner Printed Wire Board (PWB) mounting base of an extensible linear light emitting diode illumination source of the present invention; -
FIG. 7 is a cross sectional view of the inner PWB mounting base ofFIGS. 6 and 9 ; -
FIG. 8 is a drawing of a top layer of a left PWB of an embodiment of the present invention; -
FIG. 9 is a top view of an inner mounting base of a preferred embodiment; -
FIG. 10 is a drawing of a top layer of a right PWB of the present invention; -
FIG. 11 is a drawing of a web inspection system utilizing the extensible linear light emitting diode illumination source of a preferred embodiment; and -
FIG. 12 is a schematic diagram of the circuit of a preferred embodiment of the invention. -
FIG. 1 illustrates an exploded view of an assembly of an extensible linear light emittingdiode illumination source 2 of a preferred embodiment of the present invention. Theillumination source 2 includes an inner printed wire board (PWB) mountingbase 10 attached to abase 28. Right and left mirrored window supports 18, 20 are mounted to atop surface 32 of thePWB mounting base 10. Awindow 24 is mounted totop surfaces 34 of the window supports 18, 20. ThePWB mounting base 10, the mirrored window supports 18, 20, and thewindow 24 are enclosed bybrackets 22 andend caps 26. Thebrackets 22, end caps 26,base 28 andwindow 24 create an environmentally sealedassembly 2.FIG. 3 illustrates an assembled extensible linearLED illumination source 2 of a preferred embodiment. - Continuing with
FIG. 1 , theillumination source 2 includes light emitting diodes (LEDs) 16, which are positioned along an entire length of the innerPWB mounting base 10. As shown inFIGS. 6, 7 , and 9, thePWB mounting base 10 includes left andright troughs PWB segments segment 12, and the other of the cathode or anode leads of each LED are mounted on a leftLED PWB segment 14. Theillumination source 2 in alternate embodiments utilizes incandescent light, lasers, or other illumination sources in place of theLEDs 16. - Each
PWB segment illumination source 2.FIGS. 8 and 10 illustrate left andright PWB segments lead pads lead pad first lead pad 74 and the leading edge of thePWB last lead pad 76 and the trailing edge of thePWB illumination source 2 is extensible by joining right and leftsegments illumination source 2 produces a uniform illumination, i.e., without illumination gaps, along its entire length. - All linear components, including the
base 30, thePWB mounting base 10, the mirrored window supports 18, 20, thewindow 24 and thebrackets 22, as shown inFIG. 1 , can be manufactured to be of a particular length corresponding to the total number of end to endPWB segments illumination source 2. In a preferred embodiment of the invention, only the printedwiring boards illumination source assembly 2. However, in alternate embodiments of the invention, a grouping of assembled components can create an assembled segment that is held together bybrackets 24 and/or abase 30 of the required application length, as long as the grouping of assembled components maintain mechanical integrity and an environmental seal. - Referring to
FIGS. 6, 7 , and 9, the LED printedwire boards inner mounting base 10 which provides a heat sink path for dissipating heat generated by theLEDs 16. The right and leftPWB segments LEDs 16 straddle acenter ridge 64 of the mountingbase 10. Thecenter ridge 64 of a preferred embodiment acts as a continuous structural support member and efficient heat sink for theLEDs 16. TheLEDs 16 are placed in intimate contact with thecenter ridge 64 of theinner mounting base 10. In a preferred embodiment of the invention, theLEDs 16 are cemented to thecenter ridge 64 using conductive cement to increase rigidity of the LEDs as well as to provide maximum heat transfer of the heat generated by the individual LEDs to theinner mounting base 10. - As shown in
FIGS. 1, 2 , and 3, the innerPWB mounting base 10 is in intimate contact with an outer support structure andbase 28 which provides a further path for heat transfer. Abase 28 of a preferred embodiment is extruded aluminum for maximum heat dissipation.Linear cavities 36 in the base 28 provide for the circulation of cooling fluid as necessary. Fans, filters andelectrical junction boxes FIG. 11 , can be attached at each terminus of the base 28 to force cooling air through thelinear cavities 36, and/or thecable conduits 38 in thebase 28. Mountingchannels 30 are utilized for mounting theentire assembly 2 to a supportingstructure 102, as illustrated inFIG. 11 . Thecable conduits 38 are used for running electrical and power supply cables to each of thePWB segments -
FIG. 2 illustrates an exploded bottom view of the extensible linear light emittingdiode illumination source 2 ofFIG. 1 . Although for discussion purposesFIG. 2 is referred to as a bottom view, it should be appreciated that the illumination source may be mounted above or in front of a target to provide top or front lighting, or may be mounted below or behind the target to provide backlighting. The lighting configuration and type of LED utilized depends upon the application of the illumination source. For example, in a webdefect detection system 100, as shown inFIG. 11 , the material and type of defects to be detected dictates the lighting configuration, including the configurations of backlighting, front diffuse lighting, front specular lighting, dark field lighting, and oblique lighting. - Continuing with
FIG. 2 , the bottom surface of the innerPWB mounting base 10 includes anelectrical inset 40 that is aligned with a bore orhole 39 in thebase 28. Aterminal block slot 42 is recessed within theelectrical inset 40 for housing aterminal block 44. Theterminal block 44 connects power supply wiring to thePWB segment slots 46, as shown inFIGS. 7 and 9 . In the preferred embodiment eachLED illumination segment LED illumination source 2 to be extended indefinitely without undue power variations betweenLED illumination segments - The light emitting diodes of a preferred embodiment are red LEDs having a light output of 75,000 Lux. Red LEDs provide maximum illumination while providing a long lifetime, e.g., 100,000 hours. An illumination source of a preferred embodiment of the invention requires a 17V DC power source, at 3.5 amps per
PWB segment LEDs 16 in conjunction with thewindow 24 andmirror 50, as described further below, provides a highly controllable and directed light output. - The
window 24 of a preferred embodiment, as shown inFIGS. 1 and 2 , provides for mechanical protection for theLEDs 16. The type ofwindow 24 utilized in theillumination source 2 may vary according to the intended use of theillumination source 2. For example, atranslucent window 24 may be used as a diffuser in situations where diffused illumination is required. Aclear window 24 may be used for non-diffuse applications. Aspecific color window 24 may be utilized when filtered emissions are appropriate.Other windows 24 may utilize lenslets, or continuous cylindrical or other shaped lenses, to focus the light from the illumination source, e.g., theLEDs 16. -
FIGS. 1 and 4 illustrate mirrored window supports 18, 20 of a preferred embodiment. The mirror-finishedsurface 50 of thewindow support individual LEDs 16 in such a manner that a maximum amount of radiant energy is directed away from theLED illumination source 2 and towards the intended target such as a web 108, as shown inFIG. 11 . TheLEDs 16 are centered between the right mirroredwindow support 18 and the left mirroredwindow support 20. Themirrors 50 span the entire length of theLED illumination source 2 to provide a continuous, uniform, linear illumination. -
FIG. 5 is an end view of the mirroredwindow support FIG. 5 , the mirroredsurface 50 is angled with respect to the plane of thePWB segments surface 50 outwardly reflects the illumination produced by theLEDs 16. In the preferred embodiment of the invention, the inside angle α of the bracket is approximately 80 degrees, to optimize the illumination intensity since LEDs typically emit a wide angle of illumination. In other embodiments, the angle is varied depending upon the lighting conditions necessary for the specific lighting requirements of theillumination source 2. -
FIGS. 8 and 10 illustrate the top layers of the left and right printedwiring boards segments wiring board segments individual LEDs 16. In the preferred embodiment, the printed wiring board circuitry/traces are arranged in a parallel series configuration so that the failure of a single component, e.g., anLED 16, does not result in the loss of significant radiated illumination. In the example illustrated inFIGS. 8 and 9 , the bottom layers of thePWB segments right PWB 12, the anodes of these LEDs are connected in series to group B on theleft PWB 14. The parallel series continues until the end of thePWD segments LED 16 of a series fails resulting in the failure of the other five LEDs of the series, then the surrounding LEDs of the other series will provide sufficiently uniform illumination along the length of the illumination line. -
FIG. 12 illustrates the circuit realized by the right and leftPWB segments FIGS. 8 and 10 .Terminal block 44 includes a power line connected to thecathodes 150 of the ten LEDs of group A. Six LEDs are connected in ten (10)series branches 154. The anodes of the final LEDs in theseries 154 branches are connected to the power return of theterminal block 44. - The extensible linear light emitting
diode illumination source 2 may be used for surface inspection applications.FIG. 11 illustrates a high performance,web inspection system 100. Thesystem 100 utilizes smart linescan cameras 110 which optically inspect continuous materials 108, i.e., “webs”, for surface defects. Typical applications of theweb inspection system 100 includes defect detection of metals, non-woven materials, textiles, fabrics, film, paper, plastics and other materials that are manufactured as continuous web sheets. Thesystem 100 employs digital filter processing, adaptive background subtraction and advanced software algorithms to detect very small changes in surface properties. - Continuing with
FIG. 11 , theweb inspection system 100 includes anillumination source 2 of the preferred embodiment which directs light upward 106 towards the web 108. Thus,FIG. 11 illustrates a backlit web 108. In other embodiments of theweb inspection system 100, theillumination source 2 may be position above the web 108 for top lighting. Theillumination source 2, consisting of a number ofPWB segments structural support member 102 by means of thechannels 30 of thebase 28, as described above. Astructural support stand 104 supports both the bank of cameras 110 and theillumination source 102. The cameras 110, which are synchronized by anencoder 116 andsynchronization signal 132, output defect results to acomputer 130 by means of anethernet hub 112. Power supplies 130 provide power to the cameras 110 and theillumination source 2.Cooling equipment 134 provides cooling to theillumination source 2. In a preferred embodiment of the invention, thecomputer 118 controls all elements of theinspection system 100, including the cameras 110, theillumination source 2, thepower supply 130, and thecooling equipment 134. Theinspection system 100 is also connected via a network to additional equipment such as aremote monitor 124 and amodem 128 that connects to, e.g., the Internet. - Although a preferred embodiment of the invention has been described above by way of example only, it will be understood by those skilled in the field that modifications may be made to the disclosed embodiment without departing from the scope of the invention, which is defined by the appended claims.
Claims (21)
1-20. (canceled)
21. An extensible linear light source, comprising:
a first illumination segment, comprising:
a first inner mounting base having a first joining end;
a first set of linearly arranged lamps mounted on the first inner mounting base, the lamps being spaced apart by a constant distance, and one of the lamps mounted adjacent the first joining end;
a second illumination segment, comprising:
a second inner mounting base having a second joining end;
a second set of linearly arranged lamps mounted on the second inner mounting base, the lamps being spaced apart by the constant distance;
wherein the first joining end and the second joining end are constructed to align so that the lamp mounted adjacent the first joining end is spaced apart from the lamp mounted adjacent the second joining end by the constant distance.
22. The extensible light source of claim 21 , further including heat conducting adhesive disposed between each of the lamps and their respective inner mounting bases.
23. The extensible light source of claim 21 , further including heat conducting channels cooperating with the inner mounting bases.
24. The extensible light source of claim 21 , further including a rigid base for supporting and aligning the first inner mounting base and the second inner mounting base.
25. The extensible light source of claim 24 , further including heat conducting channels in the rigid base for conducting away heat generated by the lamps.
26. The extensible light source of claim 21 , wherein the inner mounting bases are aluminum with an anodized mounting surface.
27. The extensible light source of claim 21 , further including:
a first power cable powering only the first illumination segment; and
a second cable powering only the second illumination segment.
28. The extensible light source of claim 21 , further including mirrors for directing the light generated by the lamps.
29. The extensible light source of claim 28 , further including a set of elongated mirrors aligned parallel to the sets of lamps.
30. The extensible light source of claim 28 , further including a mirror coupled to each respective lamp
31. The extensible light source of claim 21 , wherein each of the lamps is an LED.
32. The extensible light source of claim 21 , wherein each of the lamps is an LED with an associated parabolic mirror.
33. An illumination segment, comprising:
an inner mounting base having a first end and a second end;
a set of linearly arranged lamps mounted on the inner mounting base between the first end and the second end, the lamps being spaced apart by a constant distance;
a first joining end at the first end of the inner mounting base, the first joining end constructed to cooperate and align with a joining end of another illumination segment;
a second joining end at the second end of the inner mounting base, the second joining end constructed to cooperate and align with a joining end of another illumination segment;
a first space between the first joining end and the lamp adjacent to the first end, the first space being less than the constant distance; and
a second space between the second joining end and the lamp adjacent to the second end, the second space being less than the constant distance.
34. The illumination segment of claim 33 , wherein the first space and the second space are both equal to one-half the constant distance
35. The illumination segment of claim 33 , further including a heat conducting adhesive disposed between each of the lamps and the inner mounting bases.
36. The illumination segment of claim 33 , further including heat conducting channels cooperating with the inner mounting bases.
37. The illumination segment of claim 33 , further including a rigid support base.
38. An extensible linear light source, comprising:
a plurality of like illumination segments aligned end to end, each illumination segment comprising:
an inner mounting base; and
a set of linearly arranged lamps mounted on the inner mounting base, the lamps being spaced apart by a constant distance; and
wherein every lamp in the extensible linear light source is spaced apart a constant distance from an adjacent lamp.
39. The illumination segment of claim 38 , further including a heat conducting adhesive disposed between each of the lamps and the inner mounting bases.
40. The illumination segment of claim 38 , further including a rigid support base.
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US20030174517A1 (en) | 2003-09-18 |
US6880952B2 (en) | 2005-04-19 |
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Legal Events
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