Extensible linear light emitting diode illumination source

A method of illuminating a target having a width with a uniform illumination across the width of the target, the method comprising the steps of:

• mounting a right printed wire board segment and a left printed wire board segment on opposite sides of a heat sink on a mounting base;
• mounting a plurality of LEDs at equally spaced intervals along said heat sink, said LEDs having first and second leads to the right and left printed wire board segments, wherein the first lead of each LED of the plurality of LEDs is connected to one of the right and left printed wire board segments, and the second lead of each LED of the plurality of LEDs is connected to the other one of the right and left printed wire board segments;
• adhering the plurality of LEDs to the heat sink of the mounting base;
• attaching at least two window support means to the inner PWB mounting base, wherein the plurality of LEDs are positioned between the at least two window support means;
• attaching a window to the at least two window support means, the window positioned so that illumination from the LEDs passes through the window;
• mounting the mounting base to a support base;
• and
• enclosing the mounting base, the at least two window support means, and at least a portion of the window utilizing at least to two brackets.

A web inspection system for detecting defects of a web having a width, the web inspection system comprising:

• a plurality of smart cameras for taking images of the web along the width, and for producing defect information;
• a computer coupled to the plurality of smart cameras for processing the defect information;
• and
• an illumination source for illuminating the web along the width, the illumination source comprising:
• an elongate mounting base having a first surface, a second surface, and a longitudinally extending heat sink on said mountain base;
• at least one right printed wire board segment mounted on said first surface to extend on one side of said heat sink and at least one left printed wire board segment mounted on said first surface to extend on the opposite side of said heat sink;
• a plurality of LEDs mounted at spaced intervals along said heat sink and attached to the at least one right printed wire board segment and the at least one left PWB printed wire board segment for producing illumination;
• a support bass attachable to the second surface of the mounting base arid having a first length, the base constructed from a heat transferring material, the support base having a plurality of interior channels extending the first length;
• at least two support members attached to a second surface of the mounting base such that the plurality of LEDs are located therebetween, each of the at least two support members comprising a mirrored surface adjacent the plurality of LEDs for directing illumination produced by the LEDs towards the web;
• a window attached to the at least two support members;
• and
• a housing for enclosing the illumination source, the housing having an open portion aligned with the window for allowing the illumination to be directed towards the web.

A linear, modular illumination system for uniform illumination of a target, comprising:

• an elongate base support member having a plurality of interior channels extending along its length, the support member having a mounting surface;
• at least one lighting segment secured to the mounting surface, the lighting segment comprising an elongate printed wiring board base having a right printed wiring board segment and a left printed wiring board segment, and a plurality of light sources mounted at spaced intervals along the base between the left and right wiring board segments, the light sources being attached to the right and left printed wiring board segments for producing illumination;
• at least one of the channels in the base comprising a cooling channel;
• a cooling fluid supply connected to said cooling channel to circulate cooling fluid in said channel and cool said light sources;
• reflecting means associated with said lighting segment for directing illumination produced by the light sources onto a target;
• and
• a housing enclosing the lighting segment and reflecting means, the housing having a window for transmitting illumination from the housing.