UV-Curable Mold with Deflecting Particles for Uniform Curing
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Solution Overview
Problem
UV-curing methods face challenges in uniformly curing photo-curable resins across thick or complexly shaped materials due to attenuation of UV radiation, making it difficult to produce fully cured articles with deep penetration and uniformity.
Innovation Solution
A mold made from UV-transparent thermoplastic polymer with embedded or adhered UV radiation deflecting particles that redirect UV light to ensure uniform curing, allowing for the production of thick-walled and complexly shaped articles by deflecting UV radiation within the mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If UV radiation is applied to cure photo-curable resins in thick or complexly shaped materials, then the curing speed is improved, but the uniformity of curing deteriorates due to UV radiation attenuation
Solution Approach 1:
The invention divides the UV irradiation into multiple segments by using a plurality of UV irradiation sources arranged at different positions and orientations. This segmentation allows each source to contribute to curing different regions of the thick or complexly shaped material, ensuring uniform curing throughout the entire volume while maintaining fast curing speed.
Solution Approach 2:
The invention applies local quality by positioning UV irradiation sources according to the specific geometry and thickness distribution of the material. Each UV source is directed at specific regions that require enhanced irradiation, creating locally optimized curing conditions that ensure uniform curing across the entire material volume.
2Speed
If conventional UV irradiation is used for thick-walled materials, then the curing speed is improved, but the penetration depth deteriorates due to UV radiation attenuation
Solution Approach 1:
The invention transitions from single-direction UV irradiation to multi-dimensional irradiation by arranging UV sources at various positions and orientations. This dimensional approach allows UV radiation to penetrate the thick material from multiple directions simultaneously, achieving adequate penetration depth throughout the entire material volume while maintaining fast curing speed.
3Strength
If high strength steel molds are used for injection molding, then the mold strength is improved, but the manufacturing cost deteriorates
Solution Approach 1:
The invention employs composite materials for the mold construction, combining materials that provide the necessary strength and rigidity with cost-effective alternatives. This composite approach maintains the required mold strength for injection molding while significantly reducing manufacturing costs compared to conventional high strength steel molds.
4Device complexity
If UV radiation is emitted in a linear manner from the UV-source, then the device complexity is reduced, but the curing completeness deteriorates for complexly shaped articles
Solution Approach 1:
The invention segments the irradiation system into multiple UV sources positioned at different locations and orientations. This segmentation enables complete coverage of complexly shaped articles by ensuring that UV radiation reaches all surfaces and internal regions, achieving thorough curing without excessive system complexity.
Solution Approach 2:
The invention incorporates curved or angled positioning of UV irradiation sources to match the geometry of complexly shaped articles. This curved arrangement ensures that UV radiation follows the contours of the material, achieving complete and uniform curing of complex shapes while maintaining reasonable system complexity.
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 approach enables efficient and uniform curing of UV-curable materials, reducing energy consumption, material waste, and manufacturing costs, while allowing for the production of complex and thick-walled articles, such as electrical insulators, with improved manufacturing flexibility.
Implementation Method 1
UV radiation deflecting particles immersed in or adhered to a surface of the mold wall
Implementation Method 2
UV radiation deflecting particles immersed in or adhered to a surface of the mold wall
Implementation Method 3
ultraviolet radiation is applied to resins such as coatings, adhesives, marking ink and photo-resists, and photocurable substances etc., to cause photo polymerization
Data Source
AI summary
A mold for molding a UV cured article in an inner volume thereof, the mold including a mold wall surrounding the inner volume, the mold including a UV-transparent polymer and UV radiation deflecting particles immersed in or adhered to a surface of the mold wall. Also provided is an apparatus including the mold and a process for molding a UV cured article.