LED Module for UV Curing with Wavelength Selection

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Solution Overview

Problem

Existing light curing systems using discharge lamps are inefficient due to unwanted emission of infrared and visible light, have short lifespan, slow switching times, and high energy consumption, posing health risks and increasing operational costs.

Innovation Solution

The use of LEDs emitting specific wavelengths of UV, IR, and visible light, with control systems for precise activation and power management, allowing for targeted radiation and reduced component count, enabling efficient curing and drying with lower energy consumption and extended lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If discharge lamps are used for UV curing, then curing function is provided, but energy consumption increases and efficiency decreases due to unwanted infrared and visible light emission

Engineering Contradiction:

Improveenergy consumptionVSAvoidenergy loss through unwanted radiation

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The patent extracts only the useful UV radiation component from the electromagnetic spectrum while eliminating unwanted infrared and visible light emission. LED modules emit monochromatic light at specific wavelengths (380-400nm for UV-A, 440-480nm for blue) that match the absorption peaks of photoinitiators, thereby avoiding energy waste in other wavelength ranges.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the radiation parameter from broad-spectrum discharge lamp emission to narrow-band LED emission. By selecting LED chips with peak wavelengths matching photoinitiator absorption characteristics, the system achieves high curing efficiency while minimizing energy consumption and heat generation.

Inventive Principle:

Principle #35Parameter changes

2Duration of action of stationary object

If discharge lamps are used for UV curing, then curing function is provided, but device lifespan is short

Engineering Contradiction:

Improvelamp lifespanVSAvoidsystem reliability

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

The patent replaces expensive, short-lived discharge lamps with more durable LED modules. LEDs have no filament or gas discharge components that fail, providing significantly extended operational life and improved system reliability without requiring frequent replacements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Speed

If discharge lamps are used for UV curing, then curing function is provided, but switching speed is slow

Engineering Contradiction:

Improveswitching speedVSAvoidtime loss during switching

Core Design Contradiction:

SpeedVSLoss of time

Solution Approach 1:

The patent replaces the thermal-mechanical heating process of discharge lamps with direct electrical excitation of LED chips. LEDs can be switched on and off instantaneously by electrical control signals, enabling rapid cycling and precise timing control for optimized curing processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Temperature

If broad-spectrum UV lamps are used, then curing coverage is provided, but heat generation increases causing negative effects

Engineering Contradiction:

Improveheat generationVSAvoidnegative effects from heat

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potential harm of excessive heat generation into a benefit by using cold LED technology. LEDs emit minimal heat compared to discharge lamps, eliminating thermal damage risks to substrates and surrounding components while maintaining effective UV curing output.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

This solution provides a more efficient and cost-effective light curing system with reduced health risks, lower energy consumption, and longer LED lifespan, enabling precise control over radiation power and rapid switching, adapted to specific chemical products.

Implementation Method 1

light emitting diodes (LEDs)... emitting electromagnetic radiations in the UV band... LEDs emitting IR radiations... LEDs emitting visible light

Methodology Applied

Scientific EffectLight emitting diode (LED): Light Emitting Diode

Implementation Method 2

curing occurs in shorter times... irradiating the material to be cured with UV radiation... chemical reactions which are catalysed by red or green visible light... chemical reactions that are catalysed by blue light

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 3

infrared (IR) radiations can be used... LEDs emitting IR radiations in the band comprised between 600 and 1400 nm... IR radiations can be used to dry the painted surface

Methodology Applied

Scientific EffectInfrared radiation: Infrared Radiation

Data Source

PatentEP3213826B1Apparatus and method for drying/curing chemical products through LED module

Publication Date: 2019.05.22 CEFLA SOC COOP

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AI summary

Module (1) for emitting radiations for the curing and/or drying of curable/dryable treatments like paints or glue applied on products (21), characterized in that it comprises: h) at least one UV LED (2), emitting between 200 and 400 nm, or one IR LED, emitting between 600 and 1400 nm; i) a control circuit (3) of said UV or IR LED (2); j) a supplying circuit (4); k) a control circuit (7) of said module (1); 1) a sensor (8) for detecting the product (21) to be cured/dried.