System and method for curing pigmented ultraviolet-cured coatings
By combining multi-wavelength UV LED lamps and a robotic system, the problem that single-wavelength UV LED lamps cannot cure colored UV coatings has been solved, achieving a highly efficient and energy-saving coating curing effect.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- GM GLOBAL TECHNOLOGY OPERATIONS LLC
- Filing Date
- 2025-01-20
- Publication Date
- 2026-06-05
AI Technical Summary
Existing single-wavelength UV LED lamps cannot effectively cure coloring UV-curable coatings, and cannot simultaneously penetrate and cure the thickness and surface of the coating.
Multiple UV LED lamps, including UV-C, UV-A, UV-V, and UV-B lamps, are used to emit different wavelengths. The distance and intensity between the lamps and the coating are precisely controlled by a robotic system and a flexible substrate to achieve multi-wavelength curing.
It achieves complete curing of colored UV-curable coatings, reducing energy consumption, carbon emissions, and production cycles, while also reducing equipment size and heat generation.
Smart Images
Figure CN122141931A_ABST
Abstract
Description
Technical Field
[0001] This disclosure generally relates to systems and methods for curing ultraviolet (UV) curable coatings. More specifically, this disclosure relates to a system and method for curing colored UV curable coatings using a lampshade comprising a UV light-emitting diode (LED) lamp. Background Technology
[0002] Currently, UV-cured coatings are cured using broad-spectrum UV lamps such as mercury-based UV lamps. Single-wavelength UV LED lamps cannot cure UV-cured coatings. The fundamental reason is that a multi-wavelength UV spectrum is required to completely cure the colored UV-cured coating. Long-wavelength UV lamps are needed to penetrate and cure the thickness of the colored UV-cured coating. At the same time, short-wavelength UV lamps are needed to penetrate and cure the surface layer of the colored UV-cured coating.
[0003] Therefore, there is a need for a new and improved UV LED lamp system and method for curing colored UV-curable coatings. Summary of the Invention
[0004] According to several aspects, a lampshade for curing coloring ultraviolet (UV) curable coatings is provided. The lampshade includes a plurality of UV light-emitting diode (LED) lamps. The plurality of UV LED lamps includes a first UV LED lamp. The first UV LED lamp emits a first wavelength. The plurality of UV LED lamps also includes a second UV LED lamp. The second UV LED lamp emits a second wavelength. The first wavelength is different from the second wavelength. The plurality of UV LED lamps emit light simultaneously. The lampshade also includes a flexible substrate. The plurality of LED lamps are disposed on the flexible substrate. The flexible substrate is conformed to the contour of the coloring UV curable coating.
[0005] In another aspect of this disclosure, the first UV LED lamp is a UV-C LED lamp. The first wavelength is the UV-C wavelength of the surface of the UV-cured coloring coating.
[0006] In another aspect of this disclosure, the second UV LED lamp is a UV-A LED lamp. The second wavelength is the UV-A wavelength of the thickness of the UV-cured coloring coating.
[0007] In another aspect of this disclosure, the second UV LED lamp is a UV-V LED lamp. The second wavelength is the UV-V wavelength at which the UV-cured coloring coating is cured.
[0008] In another aspect of this disclosure, the plurality of LED lights also include a third UV LED light. The third UV LED light is a UV-B LED light and emits UV-B wavelengths that cure the intermediate layer of the UV-curable coating.
[0009] In another aspect of this disclosure, the lampshade also includes a rear actuator. This rear actuator controls the contour of the flexible substrate.
[0010] In another aspect of this disclosure, the rear actuator maintains a desired distance between the multiple LED lights and the colored UV-cured coating.
[0011] According to several aspects, a robotic system for curing coloring ultraviolet (UV) curable coatings is provided. The robotic system includes a robotic arm. The robotic arm includes a first end and a second end. The second end is opposite to the first end. The robotic system also includes a lampshade disposed at the end of the second end of the robotic arm. The lampshade includes a plurality of UV light-emitting diodes (LEDs) disposed on a flexible substrate. The plurality of UV LEDs includes a first UV LED. The first UV LED emits light of a first wavelength. The plurality of UV LEDs also includes a second UV LED. The second UV LED emits light of a second wavelength. The first wavelength is different from the second wavelength. The plurality of UV LEDs emit light simultaneously. The robotic system also includes a flexible substrate. The flexible substrate is conformally fitted to the contour of the coloring UV curable coating.
[0012] In another aspect of this disclosure, the first UV LED lamp is a UV-C LED lamp. The first wavelength is the UV-C wavelength of the surface of the UV-cured coloring coating.
[0013] In another aspect of this disclosure, the second UV LED lamp is a UV-A LED lamp. The second wavelength is the UV-A wavelength of the thickness of the UV-cured coloring coating.
[0014] In another aspect of this disclosure, the second UV LED lamp is a UV-V LED lamp. The second wavelength is the UV-V wavelength at which the UV-cured coloring coating is cured.
[0015] In another aspect of this disclosure, the plurality of UV LED lamps also include a third UV LED lamp. The third UV LED lamp is a UV-B LED lamp and emits UV-B wavelengths for curing the intermediate layer of the UV-curable coating.
[0016] In another aspect of this disclosure, the robotic system also includes a rear actuator. This rear actuator controls the contour of the flexible substrate and maintains a desired distance between the multiple UV LEDs and the colored UV-curable coating.
[0017] In another aspect of this disclosure, the robotic system also includes a control system. This control system includes determining the position and orientation of the robotic arm relative to the colored UV-curable coating, dynamically adjusting the duration and intensity of each of a plurality of UV LEDs, and selectively turning one or more groups of UV LEDs on and off.
[0018] According to several aspects, a method for curing a coloring ultraviolet (UV) curable coating is provided. The method includes applying the coloring UV curable coating to a substrate surface. The method further includes curing a first portion of the coloring UV curable coating using a first UV light-emitting diode (LED) lamp emitting a first wavelength. The method further includes curing a second portion of the coloring UV curable coating using a second UV LED lamp emitting a second wavelength. The first wavelength is different from the second wavelength. After the first portion of the UV curable coating has cured, the second portion of the UV curable coating is cured.
[0019] In another aspect of this disclosure, the first UV LED lamp has a UV-C LED lamp. The UV-C LED lamp emits UV-C wavelengths that cure the surface layer of the UV-curable coating.
[0020] In another aspect of this disclosure, the second UV LED lamp has a UV-A LED lamp. The UV-V LED lamp emits UV-V wavelengths that allow the UV-cured coating to be cured to a depth of UV-V wavelength.
[0021] In another aspect of this disclosure, the method further includes a third UV-LED lamp for curing an intermediate layer of the UV-curable coating. The third UV-LED lamp has a UV-B LED and emits a UV-B wavelength. The UV-B wavelength is different from both the first and second wavelengths. The intermediate layer of the UV-curable coating is cured after the first portion and before the second portion.
[0022] In another aspect of this disclosure, the first UV LED lamp has a UV-V LED lamp. The UV-V LED lamp emits UV-V wavelengths that allow the UV-cured coating to be cured to a depth of UV-V wavelength.
[0023] In another aspect of this disclosure, the second UV LED lamp has a UV-C LED lamp. The UV-C LED lamp emits UV-C wavelengths that cure the surface layer of the UV-curable coating.
[0024] Further areas of application will become apparent from the description provided herein. It should be understood that these descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description
[0025] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.
[0026] Figure 1 This is a side view of a robot having a lampshade mounted on it, according to an exemplary embodiment.
[0027] Figure 2A This is a bottom view of a lampshade having multiple UV LEDs according to an exemplary embodiment;
[0028] Figure 2B This is a bottom view of an alternative embodiment of a lampshade having multiple UV LEDs according to an exemplary embodiment;
[0029] Figure 3 This is a side view of a UV-cured coating with different UV wavelengths penetrating it according to an exemplary embodiment;
[0030] Figure 4 This is an enlarged side view of an alternative embodiment of the lampshade according to an exemplary embodiment;
[0031] Figure 5 This is a flowchart of a method for curing a coloring UV-curable coating according to an exemplary embodiment;
[0032] Figure 6 This is a flowchart of another method for curing coloring UV-curable coatings according to an exemplary embodiment;
[0033] Figure 7 This is a flowchart of another method for curing coloring UV-curable coatings according to an exemplary embodiment. Detailed Implementation
[0034] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses.
[0035] refer to Figure 1 The diagram shows a side view of a robot 10 with a lampshade 12 according to the principles of this disclosure. It should be understood that the robot 10 may employ other methods besides [the lampshade 12] without departing from the scope of this disclosure. Figure 1 Various forms other than those shown. Robot 10 is programmed to cure a coloring ultraviolet (UV) curable coating 14 applied to a substrate surface 16. The UV curable coating 14 may include primers, topcoats, adhesives, and nail polish. The substrate surface 16 may include vehicle parts, such as doors, or any other items. The substrate surface 16 may also include personal nails and building materials, such as floors, walls, or any other items. Robot 10 includes a base 18, a robotic arm 20, and a controller 22.
[0036] The base 18 can be positioned on a floor surface (not shown) or on a bracket (not shown). A robotic arm 20 extends from a first end 24 to a second end 26. The second end 26 is opposite to the first end 24. The first end 24 is connected to the base 18, and the second end 26 is connected to the lampshade 12. The robotic arm 20 may include one or more joints 27 to allow the robotic arm 20 to have one or more articulation points.
[0037] The controller 22 can be housed within 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 operational control signals, such as controlling the position of the robot arm 20 and controlling the distance between the lamp housing 12 and the UV-cured coating 14. The controller 22 controls the robot arm 20 to move along a path above the substrate surface 16 and detects the distance between the UV-cured coating 14 and the lamp housing 12.
[0038] refer to Figure 2A The image shows a bottom view of the lampshade 12. The lampshade 12 has a circular shape. Multiple UV LEDs 30 are evenly arranged around the periphery of the lampshade 12.
[0039] Multiple UV LED lamps 30 include more than one type of UV LED lamp emitting more than one UV wavelength. Multiple UV LED lamps 30 may include combinations of two or more UV-A LED lamps 38, UV-V LED lamps 40, UV-C LED lamps 42, and UV-B LED lamps 44 to thoroughly cure the coloring UV-curable coating 14. The selection and combination of the two or more UV-A LED lamps 38, UV-V LED lamps 40, UV-C LED lamps 42, and UV-B LED lamps 44 depends on the curing requirements of the coloring UV-curable coating 14. Generally, the UV-C LED lamp 42 cures the surface layer 58 (of the coloring UV-curable coating 14). Figure 3 (As shown) and produces surface hardness and abrasion resistance. Then select one or two additional types of UV-V LED lamps 40, UV-A LED lamps 38, or UV-B LED lamps 44 to cure the surface layer 58 of the colored UV-curable coating 14 (as shown). Figure 3 (As shown below). In the provided example, the plurality of UV LED lamps 30 in the lampshade 12 include UV-A LED lamps 38 and UV-C LED lamps 42. The UV-A LED lamps 38 and UV-C LED lamps 42 are arranged adjacent to each other and alternately around the perimeter of the lampshade 12.
[0040] Multiple UV LED lights are controlled by a controller (such as...) Figure 1 (As shown) Control. Controller 22 is configured with a control system to control the frequency of the plurality of LED lamps 30, the intensity of the plurality of UV LED lamps 30, and the duration of the plurality of UV LED lamps 30. Controller 22 is programmed to detect the distance between the color-curing coating 14 and the plurality of UV LED lamps 30 to achieve a target intensity. The target intensity is achieved by adjusting the intensity of the plurality of UV LED lamps 30 or adjusting the distance between the UV-curing coating 14 and the plurality of UV LED lamps 30 by the controller. Controller 22 is also configured with a control system to selectively turn one or more groups of UV LED lamps 30 on and off.
[0041] refer to Figure 2B An alternative embodiment of the lampshade is indicated by reference numeral 12'. Lampshade 12' has a rectangular shape. A plurality of UV LED lamps 30 are arranged in rows along the length of lampshade 12'. In the provided example, the plurality of UV LED lamps 30 in lampshade 12' includes UV-C LED lamps 42, UV-B LED lamps 44, and UV-V LED lamps 40. The UV-C LED lamps 42, UV-B LED lamps 44, and UV-V LED lamps 40 are arranged in rows parallel to each other. Each row contains one type of UV LED lamp, and the type of UV LED lamps in each row is different.
[0042] refer to Figure 3 The diagram shows the UV wavelengths of multiple LED lamps 30. UV-A LED lamp 38 emits UV-A wavelengths 46 ranging from approximately 320 nanometers (nm) to approximately 395 nm. UV-V LED lamp 40 emits UV-V wavelengths 48 ranging from approximately 395 nm to approximately 455 nm. UV-C LED lamp 42 emits UV-C wavelengths 50 ranging from approximately 200 nm to approximately 280 nm. UV-B LED lamp 44 emits UV-B wavelengths 52 ranging from approximately 280 nm to approximately 320 nm.
[0043] Different portions of the UV-curable coloring coating 14 are cured at UV-A wavelength 46, UV-V wavelength 48, UV-C wavelength 50, and UV-B wavelength 52. The thickness 54 of the UV-A wavelength-cured coloring UV-curable coating 14 is 54. The depth 56 of the UV-V wavelength-cured coloring UV-curable coating 14 is 56. The surface layer 58 of the UV-C wavelength-cured UV-curable coating 14 is 50. The intermediate layer 60 of the UV-B wavelength-cured UV-curable coating 14 is 60.
[0044] refer to Figure 4 An enlarged side view of an alternative embodiment of the lampshade is shown and is indicated by reference numeral 61. The lampshade 61 may include, for example... Figure 2A and 2B The arrangement of multiple LEDs 30 is shown. The lampshade 61 also includes a flexible substrate 62 and a rear actuator 64. Multiple UV LEDs 30 are disposed on the flexible substrate 62. The flexible substrate 62 is made of a flexible material. Examples of flexible materials may include, but are not limited to, fabric or plastic. In the provided example, the rear actuator 64 includes multiple pistons 66 extending from the housing 68. Movement of the pistons 66 away from and towards the housing 68 sequentially alters the contour of the flexible substrate 62. The rear actuator 64 is controlled by a controller 22 (e.g., Figure 1(As shown) The control generates a real-time adjustable back force on the flexible substrate 62. The back force applied by the back actuator 64 causes the flexible substrate 62 to bend and contour to form a desired shape. The desired shape of the flexible substrate 62 matches the contour of the substrate surface 16.
[0045] As the robotic arm 20 moves the lampshade 61 on the base surface 16, the contour of the base surface 16 may change. The controller 22 controls the robotic arm 20 (e.g., ...). Figure 1 (As shown) It travels and scans the substrate surface 16 to determine the desired shape in real time. Then the controller 22 adjusts the backward force applied to the flexible substrate 62 to match the contour of the substrate surface 16.
[0046] refer to Figure 5 The diagram shows a flowchart of a method 100 for curing a colored UV-curable coating 14. Method 100 may employ a robot 10 and lampshades 12, 12', 60, or multiple robotic arms, each equipped with a specific type of UV LED lamp. Method 100 begins at step 102, where the colored UV-curable coating 14 is applied to a substrate surface 16. Method 100 proceeds to step 104.
[0047] In step 104, a UV-C LED lamp 42 is applied to the coloring UV-curable coating 14. The UV-C LED lamp 42 emits a UV-C wavelength 50 that penetrates and cures the surface layer 58 of the coloring UV-curable coating 14. Method 100 continues to step 106.
[0048] In step 106, a UV-A LED lamp 38 is applied to the coloring UV-curable coating 14. The UV-A LED lamp 38 emits a UV-A wavelength 46 that cures the thickness 54 of the coloring UV-curable coating 14. Alternatively, a UV-V LED lamp 40 is applied to the coloring UV-curable coating 14. The UV-V LED lamp 40 emits a UV-V wavelength 48 that cures the depth 56 of the coloring UV-curable coating 14. Method 100 then proceeds to step 108. In step 108, method 100 ends with a fully cured coloring UV-curable coating 14.
[0049] refer to Figure 6A flowchart of a method 200 for curing a coloring UV-curable coating 14 is shown. Method 200 begins at step 202, where the coloring UV-curable coating 14 is applied to a substrate surface 16. Method 200 proceeds to step 204. In step 204, a UV-V LED lamp 40 is applied to the coloring UV-curable coating 14. The UV-V LED lamp 40 emits a UV-V wavelength 48 that penetrates and cures the coloring UV-curable coating 14 to a depth 56. Alternatively, a UV-A LED lamp 38 is applied to the coloring UV-curable coating 14. The UV-A LED light 38 emits a UV-A wavelength 46 that penetrates and cures the coloring UV-curable coating 14 to a thickness 54. Method 200 proceeds to step 206.
[0050] In step 206, a UV-C LED lamp 42 is applied to the colored UV-curable coating 14. The UV-C LED lamp 42 emits a UV-C wavelength 50 that cures the surface layer 58 of the colored UV-curable coating 14. Method 200 continues to step 208. In step 208, method 200 ends with the colored UV-curable coating 14 fully cured.
[0051] refer to Figure 7 A flowchart of a method 300 for curing a coloring UV-curable coating 14 is shown. Method 300 begins at step 302, where the coloring UV-curable coating 14 is applied to a substrate surface 16. Method 300 then proceeds to step 304. In step 304, a UV-C LED lamp 42 is applied to the coloring UV-curable coating 14. The UV-C LED lamp 42 emits a UV-C wavelength 50 that penetrates and cures the surface layer 58 of the coloring UV-curable coating 14. Method 300 proceeds to step 306. In step 306, a UV-B LED lamp 44 is applied to the coloring UV-curable coating 14. The UV-B LED lamp 44 emits a UV-B wavelength 52 that cures the intermediate layer 60 of the coloring UV-curable coating 14. Method 300 proceeds to step 308.
[0052] In step 308, a UV-A LED lamp 38 is applied to the coloring UV-curable coating 14. The UV-A LED lamp 38 emits a UV-A wavelength 46 that cures the thickness 54 of the coloring UV-curable coating 14. Alternatively, a UV-V LED lamp 40 is applied to the coloring UV-curable coating 14. The UV-V LED lamp 40 emits a UV-V wavelength 48 that cures the depth 56 of the coloring UV-curable coating 14. Method 300 proceeds to step 310. In step 310, method 300 ends with a fully cured coloring UV-curable coating 14.
[0053] The systems and methods used for curing colored UV-curable coatings 14 offer numerous advantages. Multiple UV LED lamps 30 are lighter, smaller, use less energy, and generate less heat than UV lamps. Furthermore, the multiple UV LED lamps 30 emit a variety of wavelengths, thereby fully curing the colored UV-curable coating 14 in a single step. This reduces energy consumption, carbon emissions, production delivery cycles, manufacturing footprint, and capital investment.
[0054] The descriptions in this disclosure are merely exemplary in nature, and variations thereof that do not depart from the spirit and scope of this disclosure are intended to fall within its scope. Such variations should not be considered as departing from the spirit and scope of this disclosure.
Claims
1. A lampshade for curing coloring ultraviolet (UV) curable coatings, the lampshade comprising: A plurality of UV light-emitting diode (LED) lamps, said plurality of UV LED lamps comprising: A first UV LED lamp, wherein the first UV LED lamp emits a first wavelength; A second UV LED lamp, wherein the second UV LED lamp emits a second wavelength, and The first wavelength is different from the second wavelength. Among them, the multiple UV LEDs emit light simultaneously; and A flexible substrate, wherein the plurality of LEDs are disposed on the flexible substrate, and The flexible substrate is matched to the contour of the colored UV-curable coating.
2. The lampshade according to claim 1, wherein, The first UV LED lamp is a UV-C LED lamp, wherein the first wavelength is the UV-C wavelength for curing the surface of the coloring UV-curable coating.
3. The lampshade according to claim 1, wherein, The second UV LED lamp is a UV-A LED lamp, wherein the second wavelength is the UV-A wavelength for curing the thickness of the coloring UV-curable coating.
4. The lampshade according to claim 1, wherein, The second UV LED lamp is a UV-V LED lamp, wherein the second wavelength is the UV-V wavelength at which the coloring UV-curable coating is cured to a certain depth.
5. The lampshade according to claim 1, wherein, The plurality of LEDs also includes a third UV LED, wherein the third UV LED is a UV-B LED and emits UV-B wavelengths that cure the intermediate layer of the coloring UV-curable coating.
6. The lampshade according to claim 1, further comprising a rear actuator, wherein, The rear actuator controls the contour of the flexible substrate.
7. The lampshade according to claim 6, wherein, The rear actuator maintains the desired distance between the plurality of LEDs and the colored UV-curable coating.
8. A robotic system for curing coloring ultraviolet (UV) curable coatings, the robotic system comprising: A robotic arm, the robotic arm including a first end and a second end, the second end being opposite to the first end; A lampshade is disposed at the end of the second end of the robot arm, the lampshade comprising a plurality of UV light-emitting diode (LED) lamps disposed on a flexible substrate; The plurality of UV LED lamps include: A first UV LED lamp, wherein the first UV LED lamp emits a first wavelength; The second UV LED lamp emits a second wavelength, and The first wavelength is different from the second wavelength. Among them, the multiple UV LEDs emit light simultaneously; and The flexible substrate, wherein the flexible substrate is matched to the contour of the colored UV-curable coating.
9. The robot system according to claim 8, wherein, The first UV LED lamp is a UV-C LED lamp, wherein the first wavelength is the UV-C wavelength for curing the surface of the coloring UV-curable coating.
10. The robot system according to claim 8, wherein, The second UV LED lamp is a UV-A LED lamp, wherein the second wavelength is the UV-A wavelength for curing the thickness of the coloring UV-curable coating.