LED Curing Apparatus Passive Cooling via Convection
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Solution Overview
Problem
Existing LED curing apparatuses for printing and coating applications face challenges with overheating due to inefficient heat dissipation, leading to reduced performance and potential damage to LEDs, and existing cooling systems are complex, prone to contamination, and lack uniformity in cooling distribution.
Innovation Solution
An improved LED curing apparatus featuring a housing with finned heat sinks and controlled air pressure differentials, where air enters through an inlet cavity below the heat sink and exits through an outlet cavity above, ensuring uniform cooling along the length and reducing noise, while allowing for the reuse of existing cooling components from mercury lamp systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple axial fans are used to push air through the apparatus, then cooling effectiveness is improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts the active cooling mechanism (axial fans) from the system and replaces it with a passive cooling approach using natural convection currents. The housing design allows hot air to rise and escape through outlet openings while cooler air enters through inlet openings, eliminating the need for mechanical fans and reducing device complexity.
Solution Approach 2:
The cooling system is designed to be self-regulating through natural convection. The housing structure itself creates the cooling effect by allowing hot air to rise and escape, while cooler air automatically enters to replace it. This self-service mechanism eliminates the need for external power sources and control systems.
2Temperature
If air is pushed through the apparatus along the length, then cooling is provided, but contaminants are carried into and through the device
Solution Approach 1:
Instead of pushing air through the apparatus from one end to the other, the patent inverts the approach by allowing air to enter through inlet openings on the housing and exit through outlet openings at the top. This upward flow pattern prevents contaminants from being drawn into the apparatus along the length.
Solution Approach 2:
The patent utilizes the natural tendency of hot air to rise (which could be seen as a harmful effect causing overheating) and converts it into a beneficial cooling mechanism. The rising hot air creates natural convection currents that draw cooler air through the apparatus, providing cooling without requiring forced air flow that would introduce contaminants.
3Device complexity
If a single fan is used for cooling, then device complexity is reduced, but uniformity of cooling along the length is insufficient
Solution Approach 1:
The patent segments the cooling function by providing multiple inlet openings distributed along the housing and multiple outlet openings at the top. This segmentation allows cooler air to enter at different locations and ensures uniform cooling distribution along the length of the apparatus without requiring multiple fans.
Solution Approach 2:
The patent transitions from a linear cooling approach (single fan pushing air along the length) to a three-dimensional convection pattern. Hot air rises vertically through outlet openings at the top while cooler air enters through inlet openings distributed along the housing, creating uniform cooling throughout the apparatus volume.
4Productivity
If LED power is increased for better curing, then curing effectiveness is improved, but heat generation increases causing overheating
Solution Approach 1:
The patent converts the harmful effect of heat generation from increased LED power into a beneficial cooling mechanism. The heat causes air to rise and creates natural convection currents that draw cooler air through the apparatus, providing passive cooling that allows higher LED power without overheating.
Solution Approach 2:
The cooling system automatically responds to increased heat generation from higher LED power. As heat increases, the convection currents strengthen, drawing more cooler air through the apparatus. This self-regulating mechanism allows the system to handle variable power levels without additional cooling infrastructure.
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 provides effective heat dissipation, maintains uniform temperature and cooling across the LED curing apparatus, reduces noise, and allows for the reuse of existing components, enhancing the reliability and efficiency of the LED curing process.
Implementation Method 1
at least one finned heat sink
Implementation Method 2
at least one air passage through the housing from the or each air inlet through the or each finned heat sink to at least one air outlet
Implementation Method 3
the housing comprises an inlet cavity below the or each finned heat sink and an outlet cavity above the or each finned heat sink to maintain a higher air pressure below the or each finned heat sink and a lower air pressure above the or each finned heat sink
Data Source
AI summary
An LED curing apparatus comprising at least one LED radiation source mounted on an LED mount; a housing comprising at least one air inlet; at least one finned heat sink; and at least one air passage through the housing from the or each air inlet through the or each finned heat sink to at least one air outlet; wherein the housing comprises an inlet cavity below the or each finned heat sink and an outlet cavity above the or each finned heat sink to maintain a higher air pressure below the or each finned heat sink and a lower air pressure above the or each finned heat sink.