Post-Curing Apparatus with Multi-Directional LED and Vacuum Control
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Solution Overview
Problem
Existing devices for post-curing radiation-cured articles lack user control and efficiency, particularly in achieving low extractable content in the final products.
Innovation Solution
The apparatus includes a housing with a chamber that can be configured to be open, closed, or hermetically sealed, equipped with multiple LEDs providing light from multiple directions, a user interface for adjusting operational parameters, and a vacuum pump. The post-cure program can be inputted through the user interface, specifying light intensity, duration, and timing relative to vacuum operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing post-curing devices are used, then the curing process can be completed, but user control over operational parameters is limited and extractable content cannot be sufficiently reduced
Solution Approach 1:
The device enables dynamic adjustment of multiple operational parameters including LED light intensity, exposure time, and vacuum pressure levels. The user interface allows real-time modification of these parameters during the post-curing process, transforming a static curing device into a dynamically controllable system that adapts to specific material requirements.
Solution Approach 2:
The invention implements comprehensive parameter control including light intensity (via LED brightness adjustment), time duration (exposure time and delay timing), pressure conditions (vacuum level and timing), and temperature (via LED thermal effects). These parameter changes enable precise optimization of the post-curing process to minimize extractable content while maintaining operational flexibility.
2Manufacturing precision
If simple post-curing devices are used, then the device complexity is low, but the ability to achieve low extractable content is insufficient
Solution Approach 1:
The post-curing device is segmented into distinct functional modules: LED light sources positioned at multiple locations, vacuum system with controllable pressure, heating elements, and a user interface system. This modular segmentation allows each component to be optimized independently while working together to achieve the overall goal of reducing extractable content through coordinated control.
Solution Approach 2:
The device integrates multiple functions into a single apparatus: UV/visible light curing, vacuum degassing, heating, and programmable control. This multi-functionality eliminates the need for separate devices for each process step, reducing overall system complexity while maintaining the capability to achieve low extractable content through integrated operation.
3Manufacturing precision
If multiple LEDs are used to provide light from multiple directions, then curing uniformity is improved, but device complexity increases
Solution Approach 1:
The LED arrangement employs asymmetric positioning with LEDs located at the bottom, sides, and top of the chamber, creating non-uniform light distribution patterns that are optimized for specific sample geometries. This asymmetric configuration ensures comprehensive light coverage and uniform curing across diverse sample types without requiring symmetric complexity.
Solution Approach 2:
The transparent chamber acts as an intermediary medium that transmits light from multiple LED sources uniformly across the sample. The chamber design with transparent walls and bottom allows light penetration from all directions while protecting the sample, mediating between the multiple light sources and the sample to achieve uniform curing.
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 greater user control over the post-curing process, resulting in articles with low extractable content, improving the overall quality and consistency of the final products.
Implementation Method 1
at least two light emitting diodes (LEDs) disposed within the housing
Implementation Method 2
selectively curing the photopolymerizable composition using actinic radiation
Implementation Method 3
a vacuum pump operatively connected to the chamber
Data Source
AI summary
The present disclosure provides an apparatus for post-curing an article, as well as a system, methods, and post-cured articles. The apparatus includes a housing, a chamber disposed in the housing, at least two light emitting diodes (LEDs) disposed within the housing, and a user interface disposed on an exterior of the housing. The chamber is adaptable to each of an open, closed, and hermetically sealed configuration. The chamber includes a material transparent to actinic radiation and light from the LEDs enters the chamber from more than one direction. The user interface includes a display and program switches configured to adjust at least three operational parameters of the apparatus. The apparatus further includes a vacuum pump operatively coupled to the chamber. The system includes the apparatus and an article. An article includes layers of at least one photopolymerized crosslinked composition and a low extractable component content. A method of post-curing an article includes obtaining an article, placing the article in an apparatus, inputting a post-cure program or accessing a saved post-cure program through the user interface, and running the post-cure program. The post-cure program includes light intensity provided by a light source and length of time of light provided by the light source, plus a delay time between initiation of light provided by the light source and initiation of vacuum pulled by the vacuum pump and/or a delay time between initiation of vacuum pulled on an interior of the chamber by the vacuum pump and initiation of light provided by the light source.