Angled UVLED Curing Apparatus for Optical Fiber Coating
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Solution Overview
Problem
Conventional mercury lamps used for UV curing of glass-fiber coatings are inefficient, consuming significant power, generating excessive heat, and wasting energy due to their wide electromagnetic radiation spectrum and large size, which results in incomplete UV radiation reaching the glass fibers.
Innovation Solution
A UVLED apparatus with angled UVLED sources positioned within a cylindrical cavity with a reflective inner surface, optimized to direct UV radiation efficiently onto the glass fibers, reducing energy consumption and heat generation while improving curing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mercury lamps are used to generate UV radiation for curing, then UV radiation intensity is sufficient, but power consumption is high and heat generation is excessive
Solution Approach 1:
The patent extracts only the useful UV radiation wavelengths (300-400 nm) needed for curing while eliminating the wasted portions of the mercury lamp spectrum. UVLEDs are used that emit specifically in the 300-400 nm range, extracting only the beneficial radiation and discarding the infrared and other wavelengths that cause heat and energy waste.
Solution Approach 2:
The patent changes the spectral parameters of the UV source from broad-spectrum mercury lamps to narrow-band UVLEDs emitting specifically at 300-400 nm. This parameter change in emission wavelength and intensity distribution achieves sufficient UV radiation for curing while dramatically reducing power consumption and heat generation.
2Reliability
If mercury lamps are used to generate UV radiation, then curing can be achieved, but heat generation is excessive requiring cooling systems
Solution Approach 1:
The patent converts the harmful broad-spectrum radiation from mercury lamps into a beneficial narrow-band UV emission from UVLEDs. By using UVLEDs that emit only in the 300-400 nm range, the harmful infrared radiation that causes excessive heat is eliminated, while the useful UV curing radiation is maintained or enhanced.
3Power
If mercury lamps are used, then UV radiation is generated, but most radiation does not reach the glass fiber due to size mismatch
Solution Approach 1:
The patent applies local quality by positioning multiple small UVLEDs in close proximity to the glass fiber surface, rather than using a single large mercury lamp far from the fiber. This localized arrangement ensures that UV radiation is generated exactly where needed, maximizing the percentage of UV energy that reaches and cures the coating on the glass fiber.
4Reliability
If conventional mercury lamps are used, then UV curing can be performed, but curing time is long limiting production speed
Solution Approach 1:
The patent implements preliminary action by pre-positioning multiple UVLEDs along the glass fiber path before the fiber enters the curing zone. This arrangement ensures that UV radiation is already present and optimally positioned when the fiber arrives, enabling immediate and rapid curing without delays, thus increasing production speed while maintaining curing effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The UVLED apparatus significantly reduces power consumption and heat generation, enhancing the curing efficiency of glass-fiber coatings by directing a higher percentage of UV radiation onto the fibers, thereby increasing production rates and reducing waste.
Implementation Method 1
UVLEDs typically require significantly less energy and correspondingly generate much less heat energy than conventional UV lamps
Implementation Method 2
The coating layers may be cured, for example, using heat or ultraviolet (UV) light
Implementation Method 3
UVLED sources positioned within a cylindrical cavity with a reflective inner surface, optimized to direct UV radiation efficiently onto the glass fibers
Data Source
AI summary
A UVLED apparatus (and related system and method) provide efficient curing of an optical-fiber coating on a drawn glass fiber. The apparatus employs one or more UVLEDs that emit electromagnetic radiation into a curing space. An incompletely cured optical-fiber coating, which is formed upon a glass fiber, absorbs emitted and reflected electromagnetic radiation to promote efficient curing.