Annular LED Lamp System for Uniform Resin Curing in Laminated Glass
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lamp systems for curing resin in glass often result in non-uniform curing due to the need to periodically move UV lamps, which can lead to uneven exposure and incomplete curing, and are limited by the availability of specific electrical power sources and the fragility of fluorescent bulbs.
Innovation Solution
A lamp system with an annular LED light source that emits UV light uniformly around the resin injection system, coupled with a power regulation circuit to accommodate varying vehicle battery voltages and a durable design to replace fragile fluorescent bulbs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a UV lamp is periodically moved around the resin injection system, then all portions of the resin can be exposed to UV light, but the resin does not cure uniformly due to varying exposure times and light concentration
Solution Approach 1:
The UV light source is segmented into multiple LED elements arranged in an annular configuration around the resin injection system. Each LED segment emits UV light toward a different portion of the resin, allowing simultaneous exposure of all resin portions without moving the lamp. This segmentation resolves the contradiction by providing uniform curing while eliminating the operational complexity of lamp movement.
Solution Approach 2:
The UV light source transitions from a linear or point source to a three-dimensional annular arrangement surrounding the resin injection system. This dimensional change allows light to be delivered from multiple angles simultaneously, achieving uniform exposure across all resin portions without requiring lamp movement, thus resolving the contradiction between uniform curing and ease of operation.
2Illumination intensity
If a fluorescent bulb UV lamp is used, then UV light can be emitted for resin curing, but the bulb is fragile and requires frequent replacements
Solution Approach 1:
The invention replaces the fragile fluorescent bulb with multiple solid-state LED elements. LEDs are significantly more durable and have longer lifespans than fluorescent bulbs, eliminating the frequent replacement issue. This substitution maintains the required UV light emission intensity while dramatically improving reliability and reducing maintenance requirements.
Solution Approach 2:
The mechanical fluorescent bulb system is replaced with solid-state LED technology. This substitution eliminates the fragile glass envelope and internal mechanical structures of fluorescent bulbs, providing a more robust and reliable light source that maintains UV emission capability while resisting physical damage and extending service life.
3Adaptability or versatility
If a lamp system is designed for specific voltage (12V or 24V), then it can operate with vehicle batteries, but it cannot accommodate different electrical power sources
Solution Approach 1:
The lamp system incorporates a power regulation circuit that enables it to universally accept both 12V and 24V electrical power sources from different vehicle batteries. The circuit automatically adapts to the input voltage level, allowing the same device to function across multiple power source configurations. This universality resolves the contradiction by achieving power source compatibility while managing the necessary circuit complexity through intelligent voltage detection and regulation.
4Reliability
If the resin injection system is removed before curing, then access is improved, but voids form in the break reducing structural integrity
Solution Approach 1:
The UV light source is repositioned from a linear external lamp to a three-dimensional annular configuration that surrounds the resin injection system. This dimensional change allows the light to penetrate the resin from multiple directions simultaneously, providing adequate UV exposure even when the injection system remains in place. This resolves the contradiction by maintaining structural integrity through continuous injection system presence while achieving effective curing through multi-directional light delivery.
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
Ensures uniform curing of resin while maintaining structural integrity and reducing the need for frequent bulb replacements, with the ability to operate across different electrical power sources.
Implementation Method 1
A lamp system with an annular LED light source that emits UV light uniformly around the resin injection system
Implementation Method 2
Once the resin is injected into the break thus filling the break, the resin may be cured to form a hardened structure within the break. Often times, curing the resin may involve exposing the resin to various types of lights such as ultra-violet ("UV") light.
Data Source
AI summary
An apparatus for uniformly curing resin is described herein. The apparatus includes at least a lamp system that is to emit ultraviolet (“UV”) light. The lamp system is to emit the UV light from a light-emitting diode (“LED”) light source, which is to be energized and controlled by an electrical circuit. The electrical circuit may be provided as part of a circuit board which has power delivered thereto from a power cord. The lamp system can further include a handle having an attachment device so that the lamp system may be securely engaged with a glass surface. The lamp system may be adapted to be coupled with a resin injection system. When engaged with the resin injection system, the lamp system can deliver UV light to the injected resin so that the injected resin may be quickly and uniformly cured.