Tube Liner Curing with Dual-Wavelength LED Heating
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Solution Overview
Problem
Existing UV curing devices for tube liners in pipes are energy-inefficient and do not effectively promote polymerization due to the use of UV gas discharge lamps, which emit significant infrared heat, while modern LEDs are less efficient in delivering thermal energy for resin curing.
Innovation Solution
A curing device using a combination of LEDs emitting different wavelengths, including yellow, orange, and red light, to provide efficient thermal energy for pre-heating and curing, along with a temperature and speed control system to manage resin polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If UV gas discharge lamps are used for curing, then polymerization is promoted through heat emission, but energy efficiency deteriorates due to significant infrared heat loss
Solution Approach 1:
The patent changes the wavelength parameter of the light source from UV spectrum to visible spectrum (yellow, orange, red light with wavelengths of 560-750 nm). This parameter change allows using LED technology which converts electrical energy to light energy with much higher efficiency, while the visible light wavelengths are specifically selected to be absorbed by the resin and converted to thermal energy for effective polymerization
Solution Approach 2:
The patent substitutes the UV gas discharge lamp system with an LED-based optical heating system. The LED system replaces the inefficient gas discharge mechanism with solid-state electroluminescence, eliminating the need for gas discharge and associated infrared radiation losses while maintaining the ability to generate heat through light absorption
2Use of energy by moving object
If modern LEDs are used for curing, then energy efficiency is improved, but thermal energy delivery for resin curing deteriorates
Solution Approach 1:
The patent changes the wavelength parameter from UV to visible spectrum (560-750 nm), selecting wavelengths that match the absorption characteristics of the resin. This ensures that the LED light energy is efficiently absorbed and converted to thermal energy, solving the problem of insufficient heat delivery while maintaining LED energy efficiency
Solution Approach 2:
The patent introduces the resin itself as an intermediary that absorbs the visible light from LEDs and converts it to thermal energy. The resin's absorption properties act as a mediator between the LED light source and the polymerization process, ensuring efficient energy transfer without requiring the LED to directly emit thermal energy
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 device enhances energy efficiency and promotes effective polymerization by reducing residual monomers, improving curing quality and environmental impact.
Implementation Method 1
The curing assembly comprises at least a first LED configured to emit electromagnetic radiation of a first wavelength
Implementation Method 2
photo initiators in the resin convert the light or UV radiation into a chemical reaction that triggers polymerization
Implementation Method 3
The optical heater comprises at least a second LED configured to emit electromagnetic radiation of a second wavelength, wherein the second wavelength is different from the first wavelength, and is within the spectrum of yellow, orange and/or red light
Implementation Method 4
the thermal energy generated by absorption of light from the second LED allows to reduce a residual proportion of monomer
Data Source
AI summary
A device for curing a tube liner comprising: a curing assembly configured to cure at least a portion of the tube liner, and an optical heater configured to heat the portion of the tube liner at least before and/or after curing. The curing assembly comprises a first LED configured to emit electromagnetic radiation of a first wavelength. The optical heater comprises a second LED configured to emit electromagnetic radiation of a second wavelength, wherein the second wavelength is different from the first wavelength, and is within the spectrum of red light.