High-density solid-state lighting array for machine vision applications

An apparatus comprising:

• a lighting array for selectively illuminating a viewing area comprising,
• a plurality of individual light emitting elements formed of a semiconductor compound which directly converts a percentage of electrons which are conducted through their volume into emitted photons in one of UV, visible, and IR portions of an electromagnetic spectrum, the light emitting elements being placed within a one- or two-dimensional pattern wherein element spacing is less than or equal to 0.05",
• an electrically insulative, thermally conductive support substrate upon which the light emitting elements are attached in formation of the pattern, said support substrate specifically selected for its ability to facilitate conduction of locally generated thermal energy away from the light emitting elements while at the same time providing a sufficient degree of electrical isolation required to support parallel and series circuit construction associated with the individual light-emitting elements, and,
• a heat dissipater disposed in direct thermal contact with the thermally conductive support substrate reducing the temperature of the light-emitting elements within the array;
• a camera for acquiring images of specimens disposed in the illuminated viewing area;
• a lighting control unit in communication with the lighting array;
• and,
• a computer in communication with the camera to receive the acquired images and in communication with the lighting control unit.

A method of performing machine vision and/or process control operations, the method comprising steps of:

• providing a camera to be positioned to view specimens in a viewing area;
• providing a plurality of individual light emitting elements formed of a semiconductor compound which directly converts a percentage of electrons which are conducted through their volume into emitted photons in one of UV, visible, and IR portions of an electromagnetic spectrum;
• arranging the plurality of light emitting elements in a pattern wherein element spacing is less than or equal to 0.05" on an electronically insulative, thermally conductive support substrate;
• implementing the arranged array as a light source;
• illuminating the viewing area with the arranged array;
• conducting locally generated thermal energy away from the light emitting elements by the support substrate to a heat dissipater disposed in direct thermal contact with the thermally conductive support substrate for reducing the temperature of the light-emitting elements within the array;
• acquiring images of the specimens in the viewing area by the camera;
• and
• transmitting the acquired images to a computer.