Asymmetric Elliptical Reflectors for Radiant Energy Curing
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Solution Overview
Problem
Existing radiant energy curing devices for high aspect ratio materials, such as optical fibers, suffer from inefficiencies in energy transfer due to optical errors caused by the use of elliptical reflectors with equal minor axes, leading to reduced production rates and increased costs.
Innovation Solution
A device with primary and secondary reflectors having different elliptical shapes, where the major and minor axes lengths differ, and their focal points are aligned to improve the targeting of radiant energy, reducing optical errors and increasing energy transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If elliptical reflectors with equal minor axes are used, then the basic optical path is maintained, but optical errors occur and energy transfer efficiency is reduced
Solution Approach 1:
The patent applies asymmetry by configuring the primary and secondary reflectors with different minor axis lengths. The primary reflector has a first minor axis length while the secondary reflector has a second minor axis length that is different from the first. This asymmetric configuration corrects optical errors in the elliptical reflector system and improves radiant energy transfer efficiency to the substrate without requiring additional reflectors or complex modifications to the polymeric composition.
2Productivity
If additional reflectors are added to improve energy efficiency, then production rates can be improved, but device complexity and capital costs increase
Solution Approach 1:
The patent changes the geometric parameters of the existing reflector system by configuring the primary and secondary reflectors with different minor axis lengths. This parameter modification optimizes the elliptical reflector configuration to improve radiant energy transfer efficiency and production rates without adding additional reflectors or increasing device complexity. The solution modifies the existing system parameters rather than expanding the system.
3Measurement precision
If the minor axis lengths of primary and secondary reflectors are made different, then optical errors are reduced and energy targeting is improved, but the standard elliptical configuration is departed from
Solution Approach 1:
The patent departs from the standard symmetric elliptical configuration by making the minor axis lengths of the primary and secondary reflectors different. The primary reflector has a first minor axis length while the secondary reflector has a second minor axis length that is specifically configured to reduce optical errors and improve the precision of radiant energy targeting to the substrate. This asymmetric design prioritizes energy targeting precision over manufacturing standardization.
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 solution enhances the targeting of radiative curing energy, increasing the amount of radiant energy impinging on the substrate, thereby improving the curing process efficiency and reducing costs by minimizing the need for additional radiant exposure units.
Implementation Method 1
a source for radiant energy positioned in the elliptical space formed by the primary and secondary reflectors
Implementation Method 2
a primary reflector having a cross sectional shape that corresponds to an end portion of a first ellipse... a secondary reflector having a cross sectional shape that corresponds to an end portion of a second ellipse
Implementation Method 3
a liquid photocurable polymeric material is first applied to the surface of the fiber. This coating is then cured, for instance by irradiating the fiber with radiant energy
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Devices and methods for curing materials with radiant energy are described. The devices include a first reflector and a second reflector that are semi-ellipses. The ellipses that define the first reflector and the second reflector have axes of different lengths, and the reflectors are aligned such that the focal points of the reflectors are overlaid. A radiative energy source at a near focal point of a reflector can provide energy to cure a coating on a substrate at a far focal point of the reflector. The different sizes of the two reflectors decrease focusing error of the radiative energy and provide improved efficiency to the curing system.