Integrating Optical System for Uniform UV Curing
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Solution Overview
Problem
Conventional UV curing systems for medical devices suffer from non-uniform irradiation, leading to over-exposure and under-exposure issues, which can result in incomplete bonding and potential failure of medical devices, especially in complex geometries like catheters and IV tubing, due to the limitations of spot cure and flood light systems.
Innovation Solution
An integrating optical system with a diffuse reflective material and a chamber design that allows for uniform light distribution over multiple surfaces without direct exposure to the light source, using a feedback mechanism to adjust irradiance based on measured exitance, ensuring consistent curing across all surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional UV curing systems are used, then the curing process can be completed, but non-uniform irradiation occurs leading to over-exposure and under-exposure issues
Solution Approach 1:
The curing system is divided into multiple independent light sources positioned around the object, with each source contributing to illumination of specific surfaces. This segmentation allows uniform coverage of complex geometries including cylindrical surfaces and multi-bond line configurations, eliminating the non-uniform irradiation patterns of single-source conventional systems
Solution Approach 2:
A feedback control mechanism measures irradiance at the object surface and adjusts light source output accordingly. This closed-loop control ensures uniform UV distribution across all surfaces, preventing both over-exposure and under-exposure while maintaining reliable bonding across complex geometries
2Manufacturing precision
If multiple light sources are used to achieve uniform irradiation, then curing uniformity improves, but device complexity increases
Solution Approach 1:
The system employs a modular architecture where identical light source units can be configured in different arrangements around the object. Each module serves multiple functions: providing UV illumination, enabling flexible positioning for various geometries, and integrating with the feedback control system. This universality achieves uniform irradiation without proportionally increasing overall system complexity
3Productivity
If UV light intensity is increased to ensure complete curing, then curing speed improves, but thermal damage to the object increases
Solution Approach 1:
By dividing the total UV power across multiple spatially distributed light sources, the system achieves complete curing through cumulative irradiation while keeping the intensity at any single location moderate. This segmented approach enables complete bonding across complex surfaces without concentrating thermal energy that would cause damage
Solution Approach 2:
The feedback control mechanism monitors actual irradiance at the object surface and adjusts light output in real-time, preventing thermal accumulation while ensuring sufficient UV dose for complete curing. This controlled progression through the curing process maintains productivity while eliminating thermal damage
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 system provides reliable and repeatable uniform irradiation, reducing thermal damage and improving bonding quality by ensuring all surfaces receive the required dose without over-exposure, thus enhancing the reliability of medical device assembly.
Implementation Method 1
a chamber having a volume and formed within the first portion and the second portion when coupled together, the chamber comprising a diffuse reflective material
Implementation Method 2
Many devices are assembled using a UV activated adhesive. When UV light of the proper wavelengths and incidence (power per unit area) impinges on the adhesive at the bond line for the proper length of time, the adhesive will harden
Data Source
AI summary
Integrating optical systems and methods of use are described herein. In one embodiment, an integrating optical system comprises: a housing having a first and second portions; and a chamber having a diffuse reflective material and a volume formed within the portions when coupled together. The portions are separable to allow insertion and removal of at least one light treatable object in and out of the chamber. At least one aperture is formed in the chamber to couple to a light source and to direct light from the light source to at least a first portion of the diffuse reflective material. At least one holding structure supports the object within the volume at a location, wherein the diffuse reflective material, the aperture and the location ensure that the light is diffusely reflected to integrate the light and impact the object with substantially uniform light without movement of the object.