Lamp housing and robot system for curing a pigmented ultraviolet curable paint

Abstract

A lamp housing for curing a pigmented ultraviolet (UV) curable paint comprises multiple UV light-emitting diodes (LEDs). These multiple UV LEDs emit light simultaneously. The array includes a first UV LED and a second UV LED. The first UV LED emits a first wavelength, and the second UV LED emits a second wavelength. The first wavelength differs from the second. The lamp housing also includes a flexible substrate. The multiple LEDs are arranged on this flexible substrate, which conforms to the contour of the pigmented UV curable paint.

Description

INTRODUCTION

[0001] The present disclosure relates generally to a system and a method for curing an ultraviolet (UV) curable paint. In particular, the present disclosure relates to a system and a method for curing a pigmented UV curable paint with a lamp housing containing UV light-emitting diode (LED) light sources.

[0002] Currently, UV-curable coatings are cured using broad-spectrum UV lamps, such as mercury-based UV lamps. A single-wavelength UV LED light source cannot cure UV-curable paint. This is because multiple wavelengths of the UV spectrum are required to thoroughly cure the pigmented UV-curable paint. Long-wavelength UV light is needed to penetrate and cure a certain thickness of the pigmented UV-curable paint. Meanwhile, short-wavelength UV light is needed to penetrate and cure the skin layer of the pigmented UV-curable paint.

[0003] Therefore, there is a need for a new and improved UV LED light system and process for curing the pigmented UV-curable paint. SUMMARY

[0004] A lamp housing is provided for curing a pigmented ultraviolet (UV) curable paint, according to several specifications. The lamp housing includes multiple UV light-emitting diodes (LEDs). These multiple UV LEDs include a first UV LED emitting a first wavelength. The multiple UV LEDs also include a second UV LED emitting a second wavelength, which differs from the second wavelength. All multiple UV LEDs emit light simultaneously. The lamp housing further includes a flexible substrate. The multiple LEDs are arranged on this flexible substrate, which conforms to the contour of the pigmented UV curable paint.

[0005] In an additional aspect of the present disclosure, the first UV LED light source is a UV-C LED light source. The first wavelength is a UV-C wavelength that cures an area of ​​the pigmented UV-curable paint.

[0006] In another aspect of the present disclosure, the second UV LED light source is a UV-A LED light source. The second wavelength is a UV-A wavelength that cures a thickness of the pigmented UV-curable paint.

[0007] In another aspect of the present disclosure, the second UV LED light source is a UV-V LED light source. The second wavelength is a UV-V wavelength that cures the pigmented UV-curable paint to a certain depth.

[0008] In another aspect of the present disclosure, the plurality of LED light sources further comprises a third UV LED light source. The third UV LED light source is a UV-B LED light source and emits a UV-B wavelength that cures a middle layer of the pigmented UV-curable paint.

[0009] In another aspect of the present disclosure, the lamp housing further comprises a rear actuator. The rear actuator controls the contour of the flexible substrate.

[0010] In another aspect of the present disclosure, the rear actuator maintains a desired distance between the multitude of LED light sources and the pigmented UV-curable paint.

[0011] A robotic system for curing a pigmented ultraviolet (UV) curable paint is provided according to several specifications. The robotic system includes a robotic arm. The robotic arm has a first and a second end. The second end is opposite the first end. The robotic system further includes a lamp housing located at the end of the second end of the robotic arm. The lamp housing contains a plurality of UV light-emitting diodes (LEDs) light sources arranged on a flexible substrate. The plurality of UV LED light sources includes a first UV LED light source. The first UV LED light source emits a first wavelength. The plurality of UV LED light sources further includes a second UV LED light source. The second UV LED light source emits a second wavelength. The first wavelength differs from the second wavelength. The plurality of UV LED light sources emits light simultaneously.The robotic system also includes the flexible substrate. The flexible substrate corresponds to a contour of the pigmented UV-curable paint.

[0012] In another aspect of the present disclosure, the first UV LED light source is a UV-C LED light source. The first wavelength is a UV-C wavelength that cures an area of ​​the pigmented UV-curable paint.

[0013] In another aspect of the present disclosure, the second UV LED light source is a UV-A LED light source. The second wavelength is a UV-A wavelength that cures a thickness of the pigmented UV-curable paint.

[0014] In another aspect of the present disclosure, the second UV LED light source is a UV-V LED light source. The second wavelength is a UV-V wavelength that cures the pigmented UV-curable paint to a certain depth.

[0015] In another aspect of the present disclosure, the plurality of UV LED light sources further comprises a third UV LED light source. The third UV LED light source is a UV-B LED light source and emits a UV-B wavelength that cures a middle layer of the pigmented UV-curable paint.

[0016] In another aspect of the present disclosure, the robotic system further comprises a rear actuator. The rear actuator controls the contour of the flexible substrate and maintains a desired distance between the multitude of UV LED light sources and the pigmented UV-curable paint.

[0017] In another aspect of the present disclosure, the robot system further comprises a control system. The control system includes determining the position and orientation of the robot arm relative to the pigmented UV-curable paint, dynamically adjusting the duration and intensity of each of the plurality of UV LED light sources, and selectively switching on and off one or more of the plurality of UV LED light sources.

[0018] A method for curing a pigmented ultraviolet (UV) curable paint is provided, comprising several aspects. The method includes applying the pigmented UV curable paint to a substrate surface. It further includes curing a first portion of the pigmented UV curable paint using a first UV light-emitting diode (LED) light source emitting a first wavelength. The method also includes curing a second portion of the pigmented UV curable paint using a second UV LED light source emitting a second wavelength. The first wavelength differs from the second wavelength. The second portion of the UV curable paint is cured after the first portion has been cured.

[0019] In another aspect of the present disclosure, the first UV-LED light source features a UV-C LED light source. The UV-C LED light source emits a UV-C wavelength that cures the skin of UV-curable paint.

[0020] In another aspect of the present disclosure, the second UV LED light source features a UV-A LED light source. The UV-V LED light source emits a UV-V wavelength that cures the UV-curable paint to a certain depth.

[0021] In another aspect of the present disclosure, the process further comprises a third UV LED light source that cures a middle layer of the pigmented UV-curable paint. The third UV LED light source is a UV-B LED light source and emits a UV-B wavelength. The UV-B wavelength differs from the first wavelength and also differs from the second wavelength. The middle layer of the UV-curable paint is cured after the first layer and before the second layer.

[0022] In another aspect of the present disclosure, the first UV-LED light source features a UV-V LED light source. The UV-V LED light source emits a UV-V wavelength that cures the UV-curable paint to a depth of [missing information].

[0023] In another aspect of the present disclosure, the second UV-LED light source includes a UV-C LED light source. The UV-C LED light source emits a UV-C wavelength that hardens the skin of the UV-curable paint.

[0024] Further areas of application will become apparent from the description provided herein. It is understood that the description and specific examples serve only for illustration and are not intended to limit the scope of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. Fig. Figure 1 is a side view of a robot with a lamp housing attached to the robot according to an exemplary embodiment. Fig. Figure 2A is a view of the underside of the lamp housing with a plurality of UV LED light sources according to an exemplary embodiment. Fig. Figure 2B is a bottom view of an alternative embodiment of the lamp housing with the plurality of UV LED light sources according to an exemplary embodiment. Fig. Figure 3 is a side view of different UV wavelengths penetrating a pigmented UV-curable paint according to an exemplary embodiment. Fig. Figure 4 is an enlarged side view of an alternative embodiment of the lamp housing according to an exemplary embodiment. Fig. Figure 5 is a flowchart of a process for curing the pigmented UV-curable paint according to an exemplary embodiment. Fig. Figure 6 is a flowchart of another method for curing the pigmented UV-curable paint according to an exemplary embodiment. Fig. Figure 7 is a flowchart of another method for curing the pigmented UV-curable paint according to an exemplary embodiment. DETAILED DESCRIPTION

[0026] The following description is merely exemplary and is not intended to limit the present disclosure, application or use.

[0027] With reference to Fig. Figure 1 illustrates a side view of a robot 10 with a lamp housing 12 according to the principles of the present disclosure. It should be noted that the robot 10 can also take other forms than those shown. Fig. The robot 10 can be assumed as shown in Figure 1 without deviating from the scope of the present disclosure. The robot 10 is programmed to cure a pigmented ultraviolet (UV) curable paint 14 applied to a substrate surface 16. The UV curable paint 14 can include primers, topcoats, adhesives, and nail polishes. The substrate surface 16 can include a vehicle part, such as a door, or any other object. The substrate surface 16 can also include a person's nail and a building material, such as a floor, a wall, or another object. The robot 10 comprises a base 18, a robot arm 20, and a controller 22.

[0028] The base 18 can be positioned on a floor surface (not shown) or on a stand (not shown). The robot arm 20 extends from a first end 24 to a second end 26. The second end 26 is opposite the first end 24. The first end 24 is connected to the base 18, and the second end 26 is connected to the lamp housing 12. The robot arm 20 can include one or more joints 27, thus providing the robot arm 20 with one or more articulation points.

[0029] The controller 22 can be located inside the robot 10 or connected to the robot via a wired or wireless connection. The controller 22 is configured with a control system for operating the robot 10 and the lamp housing 12. For example, the controller 22 provides operating control signals, such as controlling the position of the robot arm 20 and the distance between the lamp housing 12 and the pigmented UV-curable ink 14. The controller 22 controls the robot arm 20 to move along a path across the substrate surface 16 and detect a distance between the pigmented UV-curable ink 14 and the lamp housing 12.

[0030] With reference to Fig. Figure 2A shows a bottom view of the lamp housing 12. The lamp housing 12 has a circular shape. A multitude of UV LED light sources 30 are evenly arranged around the circumference of the lamp housing 12.

[0031] The multitude of UV LED light sources 30 comprises more than one UV LED light source emitting more than one UV wavelength. The multitude of UV LED light sources 30 can include a combination of two or more UV-A LED light sources 38, UV-V LED light sources 40, UV-C LED light sources 42, and UV-B LED light sources 44 to thoroughly cure the pigmented UV-curable color 14. The selection and combination of the two or more UV-A LED light sources 38, UV-V LED light sources 40, UV-C LED light sources 42, and UV-B LED light sources 44 depends on the requirements for curing the pigmented UV-curable color 14. In general, the UV-C LED light sources 42 cure skin 58 (in Fig. 3 shown) of the pigmented UV-curable color 14 and create surface hardness and abrasion resistance. One or two additional types of UV-V LED light sources 40, UV-A LED light sources 38 or UV-B LED light sources 44 are then selected to be placed under the skin 58 (in Fig. 3 shown) to cure the pigmented UV-curable color 14. In the example provided, the multitude of UV LED light sources 30 in the lamp housing 12 comprises UV-A LED light sources 38 and UV-C LED light sources 42. The UV-A LED light sources 38 and the UV-C LED light sources 42 are arranged side by side and alternate around the circumference of the lamp housing 12.

[0032] The multitude of UV LED light sources is controlled by the controller (in Fig. (1 shown). The controller 22 is configured with a control system to control the frequency, intensity, and duration of the multiple UV LED light sources 30. The controller 22 is programmed to detect a distance between the pigmented curable ink 14 and the multiple UV LED light sources 30 in order to achieve a target intensity. The target intensity is achieved by the controller adjusting either the intensity of the multiple UV LED light sources 30 or the distance between the UV curable ink 14 and the multiple UV LED light sources 30. The controller 22 is also configured with the control system to selectively switch one or more UV LED light sources 30 on and off.

[0033] With reference to Fig. Figure 2B is an alternative embodiment of the lamp housing designated by reference numeral 12'. The lamp housing 12' has a rectangular shape. The plurality of UV LED light sources 30 are arranged in rows along a length of the lamp housing 12'. In the provided example, the plurality of UV LED light sources 30 in the lamp housing 12' comprises the UV-C LED light sources 42, the UV-B LED light sources 44, and the UV-V LED light sources 40. The UV-C LED light sources 42, the UV-B LED light sources 44, and the UV-V LED light sources 40 are arranged in rows parallel to each other. Each row contains one type of UV LED light source, and the type of UV LED light is different in each row.

[0034] With reference to Fig. Figure 3 illustrates the UV wavelengths of the various LED light sources 30. The UV-A LED light sources 38 emit a UV-A wavelength 46 in the range of approximately 320 nanometers (nm) to approximately 395 nm. The UV-V LED light sources 40 emit a UV-V wavelength 48 in the range of approximately 395 nm to approximately 455 nm. The UV-C LED light sources 42 emit a UV-C wavelength 50 in the range of approximately 200 nm to approximately 280 nm. The UV-B LED light sources 44 emit a UV-B wavelength 52 in the range of approximately 280 nm to approximately 320 nm.

[0035] The UV-A wavelength 46, the UV-V wavelength 48, the UV-C wavelength 50, and the UV-B wavelength 52 cure different proportions of the pigmented UV-curable color 14. The UV-A wavelength 46 cures a layer 54 of the pigmented UV-curable color 14. The UV-V wavelength 48 cures a depth 56 of the pigmented UV-curable color 14. The UV-C wavelength 50 cures the skin 58 of the UV-curable color 14. The UV-B wavelength 52 cures a middle layer 60 of the UV-curable color 14.

[0036] With reference to Fig. Figure 4 illustrates an enlarged side view of an alternative embodiment of the lamp housing and is designated by reference numeral 61. The lamp housing 61 can comprise an arrangement of the plurality of LED light sources 30, as shown in Fig. 2A and Fig. Figure 2B shows the lamp housing 61, which also includes a flexible substrate 62 and a rear actuator 64. The plurality of UV LED light sources 30 are arranged on the flexible substrate 62. The flexible substrate 62 is made of a flexible material. Examples of the flexible material include, but are not limited to, fabric or plastic. In this example, the rear actuator 64 includes a plurality of pistons 66 extending from a housing 68. The movement of the pistons 66 away from and towards the housing 68, in turn, changes a contour of the flexible substrate 62. The rear actuator 64 is controlled by the controller 22 (in Figure 2B). Fig. (1 shown), to generate a rear force on the flexible substrate 62 that adjusts in real time. The force applied by the rear actuator 64 causes the flexible substrate 62 to bend and contour to form a desired shape. The desired shape of the flexible substrate 62 corresponds to the contour of the substrate surface 16.

[0037] When the robot arm 20 moves the lamp housing 61 across the substrate surface 16, the contour of the substrate surface 16 can change. The controller 22 controls the robot arm 20 (in Fig. (shown in Figure 1) to move across and scan the substrate surface 16 in order to determine the desired shape in real time. The controller 22 then adjusts the force applied to the flexible substrate 62 to match the contour of the substrate surface 16.

[0038] With reference to Fig. Figure 5 illustrates a flowchart of process 100 for curing the pigmented UV-curable paint 14. Process 100 can use the robot 10 and the lamp housings 12, 12', 60, or multiple robot arms, each with a specific type of UV LED light source. Process 100 begins with step 102, in which the pigmented UV-curable paint 14 is applied to the substrate surface 16. Process 100 continues with step 104.

[0039] In step 104, the UV-C LED light source 42 is applied to the pigmented UV-curable color 14. The UV-C LED light source 42 emits the UV-C wavelength 50, which penetrates and cures the skin 58 of the pigmented UV-curable color 14. The process 100 continues with step 106.

[0040] In step 106, the UV-A LED light source 38 is applied to the pigmented UV-curable paint 14. The UV-A LED light source 38 emits the UV-A wavelength 46, which cures the thickness 54 of the pigmented UV-curable paint 14. Alternatively, the UV-V LED light source 40 is applied to the pigmented UV-curable paint 14. The UV-V LED light source 40 emits the UV-V wavelength 48, which cures the depth 56 of the pigmented UV-curable paint 14. The process 100 then proceeds to step 108. In step 108, the process 100 ends with a fully cured pigmented UV-curable paint 14.

[0041] With reference to Fig. Figure 6 illustrates a flowchart of process 200 for curing the pigmented UV-curable paint 14. Process 200 begins with step 202, in which the pigmented UV-curable paint 14 is applied to the substrate surface 16. Process 200 continues with step 204. In step 204, the UV-V LED light source 40 is applied to the pigmented UV-curable paint 14. The UV-V LED light source 40 emits the UV-V wavelength 48, which penetrates to a depth 56 of the pigmented UV-curable paint 14 and cures it. Alternatively, the UV-A LED light source 38 is applied to the pigmented UV-curable paint 14. The UV-A LED light source 38 emits the UV-A wavelength 46, which penetrates and cures the thickness 54 of the pigmented UV-curable paint 14. The process 200 continues with step 206.

[0042] In step 206, the UV-C LED light source 42 is applied to the pigmented UV-curable color 14. The UV-C LED light source 42 emits a UV-C wavelength 50, which cures the skin 58 of the pigmented UV-curable color 14. The process 200 continues with step 208. In step 208, the process 200 ends with a fully cured pigmented UV-curable color 14.

[0043] With reference to Fig.Figure 7 illustrates a flowchart of process 300 for curing a pigmented UV-curable ink 14. Process 300 begins with step 302, in which the pigmented UV-curable ink 14 is applied to the substrate surface 16. Process 300 then proceeds to step 304. In step 304, the UV-C LED light source 42 is applied to the pigmented UV-curable ink 14. The UV-C LED light source 42 emits the UV-C wavelength 50, which penetrates and cures the skin 58 of the pigmented UV-curable ink 14. Process 300 continues to step 306. In step 306, the UV-B LED light source 44 is applied to the pigmented UV-curable ink 14. The UV-B LED light source 44 emits the UV-B wavelength 52, which cures the middle layer 60 of the pigmented UV-curable paint 14. The process 300 continues with step 308.

[0044] In step 308, the UV-A LED light source 38 is applied to the pigmented UV-curable paint 14. The UV-A LED light source 38 emits the UV-A wavelength 46, which cures the thickness 54 of the pigmented UV-curable paint 14. Alternatively, the UV-V LED light source 40 is applied to the pigmented UV-curable paint 14. The UV-V LED light source 40 emits the UV-V wavelength 48, which cures the depth 56 of the pigmented UV-curable paint 14. Process 300 continues with step 310. In step 310, process 300 ends with a fully cured pigmented UV-curable paint 14.

[0045] The system and process for curing the pigmented UV-curable paint 14 offers numerous advantages. The multiple UV LED light sources 30 are lighter and smaller, consume less energy, and generate less heat than UV lamps. Furthermore, the multiple UV LED light sources 30 emit different wavelengths to fully cure the pigmented UV-curable paint 14 in a single step. This results in a reduction in energy consumption, carbon dioxide emissions, production lead time, manufacturing capacity, and capital investment.

[0046] The description of the present revelation is merely exemplary, and variations that do not deviate from the core of the present revelation are to be considered within the scope of the present revelation. Such variations are not to be considered as deviations from the spirit and scope of the present revelation.

Claims

Lamp housing for curing a pigmented ultraviolet (UV) curable paint, wherein the lamp housing comprises: a plurality of UV light-emitting diode (LED) light sources, wherein the plurality of UV LED light sources comprises: a first UV LED light source, wherein the first UV LED light source emits a first wavelength; a second UV LED light source, wherein the second UV LED light source emits a second wavelength, and wherein the first wavelength differs from the second wavelength, and wherein the plurality of UV LED light sources emit light simultaneously; and a flexible substrate, wherein the plurality of LED light sources is arranged on the flexible substrate, and wherein the flexible substrate conforms to a contour of the pigmented UV curable paint. Lamp housing according to claim 1, wherein the first UV LED light source is a UV-C LED light source, wherein the first wavelength is a UV-C wavelength that cures an area of ​​the pigmented UV-curable paint. Lamp housing according to claim 1, wherein the second UV LED light source is a UV-A LED light source, wherein the second wavelength is a UV-A wavelength that cures a thickness of the pigmented UV-curable paint. Lamp housing according to claim 1, wherein the second UV LED light source is a UV-V LED light source, wherein the second wavelength is a UV-V wavelength that cures to a depth of the pigmented UV-curable paint. Lamp housing according to claim 1, wherein the plurality of LED light sources further comprises a third UV LED light source, wherein the third UV LED light source is a UV-B LED light source and emits a UV-B wavelength that cures a middle layer of the pigmented UV-curable paint. Lamp housing according to claim 1, further comprising a rear actuator, wherein the rear actuator controls the contour of the flexible substrate. Lamp housing according to claim 6, wherein the rear actuator maintains a desired distance between the plurality of LED light sources and the pigmented UV-curable paint. A robotic system for curing a pigmented ultraviolet (UV) curable paint, the robotic system comprising: a robotic arm comprising a first end and a second end, the second end being opposite the first end; a lamp housing arranged at the end of the second end of the robotic arm, the lamp housing comprising a plurality of UV light-emitting diode (LED) light sources arranged on a flexible substrate; the plurality of UV LED light sources comprising: a first UV LED light source, wherein the first UV LED light source emits a first wavelength; a second UV LED light source, wherein the second UV LED light source emits a second wavelength, the first wavelength being different from the second wavelength, the plurality of UV LED light sources emitting light simultaneously; and the flexible substrate, wherein the flexible substrate conforms to a contour of the pigmented UV curable paint. Robot system according to claim 8, wherein the first UV LED light source is a UV-C LED light source, wherein the first wavelength is a UV-C wavelength that cures an area of ​​the pigmented UV-curable paint. Robot system according to claim 8, wherein the second UV LED light source is a UV-A LED light source, wherein the second wavelength is a UV-A wavelength that cures a thickness of the pigmented UV-curable paint.

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