Kaleidoscope Light Tunnel for Homogeneous UV Curing
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Solution Overview
Problem
Current UV curing methods for photopolymer printing plates face challenges in achieving homogeneous illumination, leading to uneven support shoulders and increased operational costs due to the need for bulky equipment and complex reflector geometries, which complicates the curing process and maintains symmetry during rotation.
Innovation Solution
A method and apparatus utilizing a light tunnel with mirrored walls forming a kaleidoscope-like structure, combined with a UV light source, to provide even UV light distribution and broader support shoulders, reducing waste illumination and enhancing curing efficiency by using common UV sources and inexpensive mirrors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a bank of UV emitting fluorescence tubes is used for curing, then high quality curing results are achieved, but the equipment becomes bulky and operation costs increase
Solution Approach 1:
The invention divides the illumination task into multiple reflections off separate mirror surfaces arranged in a kaleidoscope configuration, rather than using a single large bulb bank. Each mirror segment contributes to the overall illumination pattern, allowing distributed lighting without requiring a bulky single-source setup.
Solution Approach 2:
The invention transitions from a single-point light source to a distributed light distribution system using multiple reflections in three-dimensional space. The kaleidoscope arrangement of mirrors creates multiple virtual light sources through angular distribution, effectively adding spatial dimensions to the illumination geometry without increasing physical equipment size.
2Device complexity
If a single UV light source with a reflecting mirror is used, then equipment size is reduced, but homogeneous illumination of the polymer plate becomes difficult to achieve
Solution Approach 1:
The single mirror is divided into multiple mirror segments arranged in a kaleidoscope configuration. Each mirror segment reflects UV light at different angles, collectively creating a homogeneous illumination pattern across the polymer plate surface without requiring a large or complex single-source setup.
Solution Approach 2:
Multiple mirror surfaces act as intermediaries that redirect UV light from a compact source to achieve uniform distribution. The mirrors serve as mediating elements that transform the point-source radiation into a distributed illumination field, solving the homogeneity problem without increasing source size.
3Illumination intensity
If rotational exposure is used to achieve symmetric support shoulders, then illumination coverage is improved, but maintaining symmetry in the circumference versus axial direction becomes difficult
Solution Approach 1:
The invention uses a symmetric kaleidoscope mirror arrangement that creates symmetric virtual light sources through geometric reflection patterns. This symmetric configuration inherently produces uniform support shoulders in both circumferential and axial directions without requiring rotational motion, eliminating the symmetry maintenance problems associated with rotation.
Solution Approach 2:
The invention replaces rotational exposure with a multi-angular reflection geometry that distributes light symmetrically in three-dimensional space. The kaleidoscope mirror arrangement creates illumination from multiple directions simultaneously, achieving symmetric support shoulders through geometric symmetry rather than temporal rotation.
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 achieves more even UV light distribution, broader support shoulders, and reduced operational costs by improving the homogeneity of UV light exposure, making the curing process more efficient and robust for photopolymer printing plates.
Implementation Method 1
A light tunnel of light reflective, e.g., mirrored walls and having a polygonal cross-section like a kaleidoscope... producing light radiation by a light source located at or near one end... to the inside of the light tunnel towards the other end of the light tunnel... including towards the reflective inner surfaces of the walls
Implementation Method 2
producing light radiation by a light source located at or near one end... to the inside of the light tunnel... operating the light source to cure the plate material by applying light radiation
Data Source
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AI summary
The present application concerns a method of curing a photo-curable printing plate, comprising: (i) providing a light exposure unit comprising a light tunnel having a cross-section and a plurality of walls (303) each wall having a reflective inner surface (311); (ii) placing a photo-curable printing plate near the light exposure unit having a length, a cross-section, and a pair of ends being a source end and a plate end, the plate having a printing surface placed with the printing surface closer to the plate end than to the source end with the printing plate substantially parallel to the cross-section of the light exposure unit; (iii) producing light radiation by a light source (301) located at or near one end, called the source end of the light tunnel to the inside of the light tunnel towards the other end of the light tunnel, called the plate end, including towards the reflective inner surfaces (311) of the walls (303); and (iv) operating the light source to cure the plate material by applying light radiation for a time sufficient for curing; wherein the cross-section of said light tunnel is polygonal like a kaleidoscope and has at least four of said walls (303), wherein said at least four walls (303) consist of pairs of walls (303), each of said pairs of walls (303) having a first wall and a second wall opposite to and parallel to said first wall, said reflective inner surface (311) of said first wall (303) facing said reflective inner surface (311) of said second wall (303).