Methods and systems relating to solid state light sources for use in industrial processes

1. A light module comprising:

an array of solid-state light emitters mounted on or formed in a thermally transmissive substrate providing electrical circuitry patterns for coupling with the solid-state emitters, the substrate comprising a ceramic or semiconductor material comprising one or more of alumina, aluminum nitride, sapphire, silicon carbide, and/or semiconductor silicon wherein the density of light emitters in the array is at least 1 emitter per 6.25 mm 2 ;

a lens array layer disposed over the array of solid-state emitters, the lens array having a plurality of lenses formed therein, each lens being optically coupled to one or more light emitters, the lens array being adjacent to the emitters and the substrate surrounding individual emitters;

a temperature control system for dissipating heat away from the light emitters; and

wherein the lens array layer and lenses formed therein comprise a monolithically molded layer of material in direct contact with the emitters and surrounding substrate.

2. The light module of claim 1 , wherein the molded material comprises a gel.

3. The light module of claim 1 , wherein the molded material comprises an epoxy, gel, acrylic, urethane, or moldable glass.

4. The light module of claim 1 wherein the temperature control system comprises one or more coolant channels or tubes adjacent the substrate.

5. A light module comprising:

an array of solid-state light emitters mounted on or formed in a thermally transmissive substrate providing electrical circuitry patterns for coupling with the solid-state emitters, the substrate comprising a ceramic or semiconductor material

wherein the density of light emitters in the array is at least 1 emitter per 6.25 mm 2 ;

a lens array layer disposed over the array of solid-state emitters, the lens array having a plurality of lenses formed therein, each lens being optically coupled to one or more light emitters, the lens array being adjacent to the emitters and the substrate surrounding individual emitters;

a temperature control system for dissipating heat away from the light emitters; and

wherein the module is associated with a power control subsystem that controls power so that, as to at least one of the plurality of solid-state light emitters, the power waveform is any one of, or any combination of two or more of: pulsed power supplied at regular, repeating or varying on/off periods or frequencies; pulsed power supplied at any of various current levels; pulsed power supplied at currents greater than the solid-state light emitter's specifications; pulsed power supplied at varying current levels; pulsed power supplied at ramped up current levels; pulsed power supplied at ramped down current levels; arbitrary voltage and current supplied at any of various pulse repetition rates and duty cycles; and/or power supplied with sinusoidal or sinusoid-like variations in current levels.

6. A light module comprising:

an array of solid-state light emitters mounted on or formed in a thermally transmissive substrate providing electrical circuitry patterns for coupling with the solid-state emitters, the substrate comprising a ceramic or semiconductor material

wherein the density of light emitters in the array is at least 1 emitter per 6.25 mm 2 ;

a lens array layer disposed over the array of solid-state emitters, the lens array having a plurality of lenses formed therein, each lens being optically coupled to one or more light emitters, the lens array being adjacent to the emitters and the substrate surrounding individual emitters;

a temperature control system for dissipating heat away from the light emitters; the light emitters being coupled to a common controller; and further comprising a fixture for holding a work object, the fixture arranged relative to the light module so that a work object may be exposed to light from the module to effect a curing or inspection of the work object with a predetermined wavelength of light for effecting the curing or inspection.

7. The light module of claim 6 , wherein the fixture provides fluid flow over the work object during light exposure, and the light module's emitters comprise emitters for emitting in the UV bandwidth.

8. A plurality of light modules, each light module comprising:

an array of solid-state light emitters mounted on or formed in a thermally transmissive substrate providing electrical circuit patterns for coupling with the solid-state emitters, the substrate comprising a ceramic or semiconductor material

wherein the density of light emitters in the array is at least 1 emitter per 6.25 mm 2 ;

a lens array layer disposed over the array of solid-state emitters, the lens array having a plurality of lenses formed therein, each lens being optically coupled to one or more light emitters, the lens array being adjacent to the emitters and the substrate surrounding individual emitters;

a temperature control system for dissipating heat away from the light emitters;

the light emitters being coupled to a common controller; and

wherein the plurality of light modules are arranged in at least one of a line or an array.

9. The light module of claim 8 , further comprising motive means that provides for movement relative to a target area along both a y-axis and an x-axis.

10. The light module of claim 8 wherein the lens array layer comprises a gel material.