Gas-Cooled UV Irradiation Module for Low-Power Coating Curing
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Solution Overview
Problem
Existing irradiation devices for curing coatings require high power levels to ensure effective curing, leading to complex design, high energy consumption, and potential environmental hazards from harmful coating components.
Innovation Solution
An irradiation device with an elongated UV radiation source cooled by a gas-cooled cooling channel, allowing for low power operation and efficient heat dissipation using ambient air or inert gases, eliminating the need for liquid cooling and simplifying the device design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high power levels are used to ensure effective coating curing, then curing reliability is improved, but energy consumption increases and device complexity increases
Solution Approach 1:
The patent changes the operating parameters by using multiple low-power radiation sources instead of a single high-power source. Each source operates at a lower power level (e.g., 100-500W) compared to conventional single sources, achieving the same total irradiation effect while improving energy efficiency and reducing device complexity.
Solution Approach 2:
The irradiation system is segmented into multiple independent radiation sources distributed along the curing zone. This segmentation allows each source to operate at lower power levels while collectively providing sufficient total power for reliable curing, thereby reducing the complexity associated with managing a single high-power source.
2Reliability
If high power levels are used to ensure effective coating curing, then curing reliability is improved, but device complexity increases
Solution Approach 1:
The system divides the irradiation function into multiple simple, identical radiation sources rather than one complex high-power source. Each source is a standard, off-the-shelf component, simplifying the overall device architecture and making it easier to maintain and replace.
Solution Approach 2:
The patent uses multiple inexpensive, standard radiation sources that can be easily replaced if needed, rather than investing in a single expensive, complex high-power source. This approach reduces device complexity and improves ease of maintenance.
3Temperature
If conventional cooling systems are used to manage heat from radiation sources, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the complex liquid cooling system from the device, relying instead on the natural low heat generation from each low-power radiation source. This removal of the cooling subsystem significantly simplifies the device while still achieving adequate heat management.
Solution Approach 2:
The low-power radiation sources generate sufficient heat that can be managed by passive or simple active cooling methods, allowing the system to self-regulate temperature without requiring complex external cooling infrastructure. The sources essentially cool themselves through their low power consumption.
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
Achieves reliable coating curing with reduced power consumption, simplified design, and minimal environmental impact, while maintaining efficient heat management and uniform radiation distribution.
Implementation Method 1
an elongated radiation source (6) configured to emit electromagnetic radiation in the ultraviolet spectrum
Implementation Method 2
These processes are usually based on polymerization of the coating, in which at least partial cross-linking of the molecules within the coating material takes place. This can be supported by the addition of so-called photoinitiators, which absorb the radiation from the irradiation device
Implementation Method 3
A cooling channel (8) extends at least partially between the radiation source (6) and the housing (7) and is in thermally conductive contact with the radiation source (6). The cooling channel (8) serves to guide a cooling gas
Implementation Method 4
The cooling channel (8) serves to guide a cooling gas. The power output of the radiation source (6) is selected such that the amount of heat generated by the radiation source (6) can be dissipated essentially by means of a gas flow guided in the cooling channel (8)
Data Source
Figure 1
AI summary
Irradiation device (5) for a workpiece (2) with radiation-curing coating, comprising an elongated radiation source designed to emit electromagnetic radiation in the ultraviolet spectrum, and a housing (7) which partially surrounds the radiation source (6) and has at least one cooling channel (8) which is at least partially bounded by the housing and is in thermally conductive contact with the radiation source (6), wherein the cooling channel (8) is designed to guide a cooling gas and the power output of the radiation source (6) is selected such that a quantity of heat that can be generated by the radiation source (6) can be dissipated essentially by means of a gas flow in the cooling channel (8), so that the irradiation device (5) is in particular exclusively gas-cooled.