LED Light Guide Exposure Device for UV Curing
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Solution Overview
Problem
Conventional mercury-arc lamp systems for curing ultraviolet (UV) curable photosensitive compositions have a short lifespan, require monitoring and adjustment due to nonlinear degradation, generate excessive heat, and emit a broad spectrum of light, including infrared (IR) radiation, which necessitates costly heat-rejecting filters and reduces efficiency. In contrast, LED systems offer longer lifespan and reduced heat but often have lower output power, making them insufficient for high-speed industrial applications.
Innovation Solution
A light guide exposure device featuring a single array of UV/violet light emitting diodes (LEDs) positioned directly adjacent to a flexible light guide without intermediate optical elements, ensuring maximum light intensity and uniformity, with adjustable power supply and cooling systems to maintain optimal light output and temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If mercury-arc lamps are used for UV curing, then high output power and broad spectrum coverage are achieved, but short lifespan, nonlinear degradation requiring monitoring, and excessive heat generation occur
Solution Approach 1:
The patent changes the fundamental parameter of the light source from mercury-arc lamp to LED, transforming the operating characteristics. LEDs provide longer lifespan, linear degradation, and adjustable output power while maintaining UV curing capability, thus resolving the contradiction between high power and short lifespan.
2Power
If mercury-arc lamps are used, then high UV output is achieved, but broad spectrum including IR radiation requires heat-rejecting filters and temperature resistant optics
Solution Approach 1:
The patent extracts the harmful IR radiation component by selecting LEDs that emit primarily in the UV/violet spectrum without significant IR content. This eliminates the need for heat-rejecting filters and temperature resistant optics, simplifying the overall system while maintaining high UV output.
3Reliability
If conventional LED arrays are used, then longer lifespan and reduced heat are achieved, but lower output power makes them insufficient for high-speed industrial applications
Solution Approach 1:
The patent segments the LED array into multiple individual LED elements arranged in a specific pattern, allowing independent control and optimization of each element. This segmentation enables higher total output power while maintaining the reliability benefits of LED technology, resolving the contradiction between lifespan and power output.
4Stability of the object's composition
If optical elements are placed between LED and light guide, then light distribution is improved, but light intensity and uniformity are reduced
Solution Approach 1:
The patent uses the light guide itself as the intermediary element that directly receives light from the LED array without additional optical elements. The light guide's proximal end is positioned to receive light directly, and its distal end delivers uniform light to the photosensitive material, eliminating the need for intermediate optics that would reduce intensity.
5Speed
If mercury-arc lamps are kept on during stand-by periods, then quick startup is achieved, but much of the bulb life is lost during warm-up and cool-down cycles
Solution Approach 1:
The patent enables periodic on/off operation of the LED array without the warm-up and cool-down cycles required by mercury-arc lamps. LEDs can be quickly switched on and off, allowing the system to operate only during actual curing tasks, thereby extending the effective lifespan while maintaining fast startup when needed.
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 improved uniformity and intensity of light delivery to photosensitive compositions, extending LED lifespan, reducing heat generation, and enabling faster curing of industrial materials with adjustable power and temperature management, overcoming the limitations of both mercury-arc and conventional LED systems.
Implementation Method 1
UV/violet light generated by light emitting diodes and directed to the photosensitive composition by the light guide
Implementation Method 2
a flexible light guide having a proximal end and a distal end; said proximal end defining a proximal end diameter
Implementation Method 3
curing photosensitive compositions by ultraviolet (UV)/violet light generated by light emitting diodes
Data Source
AI summary
The invention provides a light guide exposure device comprising light emitting diodes arranged in a single array defining an array width and a flexible light guide having a proximal end and a distal end; the proximal end defining a proximal end diameter. The array is positioned in substantial alignment with the light guide proximal end to direct substantially all of the light from the array to the proximal end. There is no optical element between the light emitting diodes and the proximal end which optical element would decrease the intensity of light directed from the light emitting diodes to the proximal end. The array width is substantially equal to the proximal end diameter.