LED UV Curing Machine with Independent Thermal Control
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Solution Overview
Problem
Conventional machines processing UV curable coatings rely on high-energy lamps, which generate intense and harmful UV radiation and heat, making it difficult to control infrared energy and posing risks to coated substrates, particularly in applications like printed circuit board assemblies.
Innovation Solution
A machine that processes coatings using LED-based UV sources in conjunction with controlled heating and humidity, allowing for adjustable UV and IR radiation emission, and independent convection/infrared heating modules to optimize curing without the need for mercury-based lamps, thereby reducing heat damage and enhancing product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional high-energy lamps are used to process UV curable coatings, then UV radiation intensity is sufficient for curing, but excessive heat and infrared energy are generated causing damage to coated substrates
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional high-energy lamps to LED-based UV sources, which operate at different spectral and thermal parameters. LED UV sources emit UV radiation at specific wavelengths (365-395 nm) with significantly reduced infrared energy output, changing the energy distribution parameters to achieve effective curing while minimizing heat damage to temperature-sensitive substrates
Solution Approach 2:
The patent segments the heating function from the UV curing function by introducing separate convection heating modules and infrared heating modules. This allows independent control of UV radiation intensity and thermal energy application, enabling the system to deliver sufficient UV intensity for curing while controlling the temperature profile to prevent substrate damage
2Reliability
If conventional high-energy lamps are used, then UV curing can be achieved, but control over infrared energy is difficult and harmful to substrates
Solution Approach 1:
The patent extracts the harmful infrared energy component from the UV curing process by replacing conventional lamps that emit both UV and IR radiation with LED UV sources that primarily emit UV wavelengths. This separation removes the harmful IR energy while retaining the necessary UV curing capability, and the extracted thermal control functions are independently managed through dedicated heating modules
Solution Approach 2:
The patent introduces controlled intermediary heating elements (convection and infrared modules) that act as mediators between the UV curing process and the substrate. These intermediaries provide necessary thermal energy for curing while being independently controllable to prevent excessive heat buildup and damage to temperature-sensitive substrates
3Object-affected harmful factors
If LED-based UV sources with controlled heating are used, then heat damage is reduced, but device complexity increases due to multiple heating modules and control systems
Solution Approach 1:
The patent applies universality by designing a integrated processing chamber that houses multiple functional modules (LED UV sources, convection heating, infrared heating, humidity control) within a single system. This multi-functional design allows the system to perform UV curing, convective heating, infrared heating, and humidity control in one unified apparatus, managing complexity through functional integration rather than separate standalone units
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 enables efficient curing of UV curable coatings with reduced risk of heat damage, improved product quality, and energy conservation by providing closed-loop control of radiation, allowing for faster throughput and safer operation.
Implementation Method 1
A machine includes one or more LED-based UV radiation sources
Implementation Method 2
exposing the treated product to the emitted UV radiation
Implementation Method 3
independent convection/infrared heating modules
Implementation Method 4
independent convection/infrared heating modules
Implementation Method 5
A machine includes one or more LED-based UV radiation sources, a heating zone, a humidity provider
Data Source
AI summary
A machine can include a UV zone that includes LED-based UV radiation sources; and a controller that controls conditions within the machine to regulate temperature of the LED-based UV radiation sources.