Inline LED Curing Detection in 3D Printers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In 3D object printers using UV curable inks, underperforming LEDs in the curing light source can lead to incomplete curing of the ink, resulting in the emission of volatile organic compounds (VOCs) and potential wiping off of the printed ink, due to inadequate light emission.
Innovation Solution
An inline detection and correction system that includes a test plate and an infrared camera to assess the thermal profile of the curing light source, identifying underperforming LEDs and adjusting the intensity of adjacent LEDs to ensure proper curing, thereby maintaining the light intensity within a predefined threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a curing light source is used to apply light to cure UV curable ink, then the ink is cured and bonded to the article, but if the curing light source malfunctions or does not emit proper light, the ink is not completely cured leading to VOC emissions and ink wiping
Solution Approach 1:
The patent implements a test plate positioned in the light path before the actual printing process. The test plate receives light from the curing source and its thermal profile is measured to detect underperforming LEDs before they can cause incomplete curing of actual ink. This preliminary detection prevents the harmful effects from occurring.
Solution Approach 2:
The system continuously monitors the thermal profile of the test plate and provides feedback about the curing light source performance. When underperforming LEDs are detected, the system can alert operators or automatically adjust the curing process to maintain complete ink curing and prevent VOC emissions.
2Object-affected harmful factors
If UV curable ink is not completely cured, then VOCs are emitted and ink may be wiped off, but implementing detection and correction systems increases system complexity
Solution Approach 1:
The patent introduces a test plate as an intermediary object that absorbs light from the curing source and converts it to thermal energy. This intermediary allows indirect measurement of light intensity through thermal profiling, simplifying the detection mechanism compared to direct optical sensors while still effectively monitoring curing source performance.
Solution Approach 2:
The system replaces complex optical detection mechanisms with thermal detection using an infrared camera to measure the thermal profile of the test plate. This substitution simplifies the detection system while maintaining effectiveness in identifying underperforming LEDs.
3Reliability
If the curing light source emits insufficient light, then ink curing is incomplete, but increasing light intensity to compensate increases energy consumption
Solution Approach 1:
The patent identifies specific underperforming LEDs through thermal profiling of the test plate and allows for targeted correction. Instead of increasing intensity of all LEDs, the system can focus on compensating only the identified underperforming LEDs or their adjacent LEDs, reducing unnecessary energy consumption while maintaining curing completeness.
Solution Approach 2:
The system dynamically adjusts curing parameters based on real-time thermal profile measurements. When underperforming LEDs are detected, the system can modify the curing process parameters such as extending exposure time or adjusting intensity of specific LEDs rather than uniformly increasing energy consumption across the entire curing array.
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 complete curing of UV inks, reducing VOC emissions and preventing ink wiping, by detecting and correcting underperforming LEDs in real-time during the printing process.
Implementation Method 1
assess the thermal profile of the curing light source
Implementation Method 2
an inline detection and correction system coupled to the curing light source... an infrared camera to assess the thermal profile
Implementation Method 3
a UV light source is used to cure the ink. The UV light source may be used to initiate a photochemical reaction that generates a crosslinked network of polymers
Data Source
AI summary
A print system and a method for detecting and correcting underperforming LEDs in-line of a 3D object printer are disclosed. For example, the print system includes a plurality of printheads arranged in a two-dimensional array, a curing light source, an inline detection and correction (IDC) system, a movable member to hold an object and a test plate and a controller to control movement of the movable member to move the object and the test plate past the array of printheads, to operate the plurality of printheads to eject a marking material onto the object as the object passes the two-dimensional array of printheads, to operate the curing light source apply energy to the test plate and to cure the marking material, and to operate the IDC system to read the test plate to confirm that the curing light source is operating correctly based on a reading of the test plate.