LED Curing Head with UV-Transparent Coolant for Pipeline Linings
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Solution Overview
Problem
Existing pipeline renovation devices using UV radiation for curing resin linings pose health risks to workers due to harmful UV emissions and are noisy, requiring high-power compressors or fans for cooling, limiting their use and efficiency.
Innovation Solution
A pipeline renovation device utilizing light-emitting diodes (LEDs) with a liquid coolant cooling system, operating at 30 V for electrical safety, and emitting electromagnetic radiation in the 200-900 nm range for resin curing, eliminating the need for noisy compressors or fans and providing efficient cooling through radiators surrounded by liquid coolant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If UV radiation is used for curing resin lining, then curing effectiveness is improved, but health safety deteriorates due to harmful UV emissions
Solution Approach 1:
The patent changes the spectral parameters of the radiation source from UV range (200-400 nm) to visible light range (400-900 nm), specifically using blue light at 450 nm wavelength. This parameter change maintains the photopolymerization curing effectiveness while eliminating the harmful UV radiation that threatens worker health and safety.
2Temperature
If high-power compressors or fans are used for cooling, then cooling efficiency is improved, but device complexity and noise increase
Solution Approach 1:
The patent implements a passive cooling system where the resin lining itself serves as the coolant. The liquid resin flows through channels in the curing device, absorbing heat from the LEDs and curing simultaneously. This self-service approach eliminates the need for external compressors or fans, reducing device complexity and noise while maintaining effective cooling.
3Temperature
If high-power compressors or fans are used for cooling, then cooling efficiency is improved, but energy consumption increases
Solution Approach 1:
The resin lining acts as a heat sink and coolant, absorbing thermal energy from the LEDs during the curing process. This converts waste heat into useful thermal energy for the curing reaction, eliminating the need for additional energy-consuming cooling systems while improving overall energy efficiency of the process.
4Object-affected harmful factors
If visible light is used for curing, then health safety is improved, but curing speed may deteriorate compared to UV
Solution Approach 1:
The patent uses blue light at 450 nm wavelength which matches the absorption peak of common photoinitiators used in resin linings. By optimizing the wavelength parameter and using high-intensity visible light LEDs, the curing speed with visible light is made comparable to or even faster than UV curing, while eliminating health hazards.
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 device achieves energy-saving, low-noise operation, allowing for safe nighttime use and significantly improved cooling efficiency, enabling higher power levels and faster resin curing rates compared to traditional methods, while ensuring electrical safety and reducing health hazards.
Implementation Method 1
light-emitting diodes (LEDs) with a liquid coolant cooling system, operating at 30 V for electrical safety, and emitting electromagnetic radiation in the 200-900 nm range for resin curing
Implementation Method 2
resin curable with electromagnetic radiation generated by light-emitting diodes
Implementation Method 3
providing efficient cooling through radiators surrounded by liquid coolant
Implementation Method 4
liquid coolant cooling system
Data Source
Figure 1~3
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Figure 9~14
AI summary
A device for curing pipeline inner resin linings (38) using an elastic lining sleeve (39) soaked with a resin curable with electromagnetic radiation, the metal body (1) of the device being equipped with thermally conducting plates (28) in which LEDs (27) are mounted generating electromagnetic radiation with wavelengths from the range 200-900 nm capable to cure the resin compound of the sleeve on inner surface of the pipeline according to the invention is characterised in that it is equipped with at least one radiator (13) and/or (23) provided with grooves (11, 23') carrying the heat away directly to coolant (40) transparent to UV radiation, whereas the radiator (13) is formed in the profiled portion (9) of an indentation (6) of the body (1), and radiator (23) is formed in the profiled face portion of the front cover (20) of the body.