UV Curing Apparatus Oxygen Control via Segmented Gas Ports
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ultraviolet curing technologies face challenges in controlling the environment, particularly oxygen and nitrogen concentrations, which can lead to variations in photopolymerization reactions and product quality.
Innovation Solution
An ultraviolet curing apparatus and method that includes a roller for guiding a resin-coated film, nitrogen gas introduction ports, an oxygen concentration meter, and a controller to regulate air and nitrogen gas introduction, ensuring the oxygen concentration is within a preset range between 500 ppm and 5% to control the crosslinking reaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nitrogen gas is introduced to control oxygen concentration, then photopolymerization reaction is improved, but device complexity increases
Solution Approach 1:
The gas introduction system is divided into multiple independent ports (first nitrogen gas introduction port, second nitrogen gas introduction port, and air introduction port) positioned at different locations. This segmentation allows independent control of gas flow from each port, enabling precise control of oxygen concentration in the irradiation region without requiring a single complex control mechanism.
Solution Approach 2:
The system incorporates an oxygen concentration meter that continuously measures the oxygen concentration in the irradiation region and feeds this information back to the controller. The controller adjusts the gas flow rates from the nitrogen gas introduction ports and air introduction port based on this feedback, maintaining optimal oxygen concentration (500-1000 ppm) for controlled photopolymerization reaction.
2Manufacturing precision
If multiple gas introduction ports are used, then oxygen concentration control is improved, but manufacturing cost increases
Solution Approach 1:
The gas introduction system is divided into multiple independent ports (first nitrogen gas introduction port, second nitrogen gas introduction port, and air introduction port) positioned at different locations. This segmentation allows independent control of gas flow from each port, enabling precise control of oxygen concentration in the irradiation region without requiring a single complex control mechanism.
Solution Approach 2:
The system uses standard gas cylinders for nitrogen and air supplies, and the controller automatically adjusts gas flow rates based on oxygen concentration measurements. The gas flow rates are controlled through simple flow control mechanisms rather than complex regulation systems, making the apparatus relatively easy to manufacture while maintaining precise control.
3Reliability
If real-time oxygen concentration measurement is implemented, then crosslinking reaction control is improved, but device complexity increases
Solution Approach 1:
The system incorporates an oxygen concentration meter that continuously measures the oxygen concentration in the irradiation region and feeds this information back to the controller. The controller adjusts the gas flow rates from the nitrogen gas introduction ports and air introduction port based on this feedback, maintaining optimal oxygen concentration (500-1000 ppm) for controlled photopolymerization reaction.
Solution Approach 2:
The controller automatically adjusts gas flow rates based on oxygen concentration measurements without requiring manual intervention. The system self-regulates the gas introduction to maintain optimal conditions for crosslinking reaction, reducing the need for complex manual control mechanisms.
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 allows for precise control of the crosslinking reaction, preventing defects such as cracking or warping and ensuring uniform curing of the resin, thereby improving product yield and quality.
Implementation Method 1
an oxygen concentration meter for measuring an oxygen concentration between the film and the UV irradiation portion
Implementation Method 2
a UV irradiation portion for irradiating the film with ultraviolet rays from between the first nitrogen gas introduction port and the second nitrogen gas introduction port
Data Source
AI summary
An ultraviolet curing apparatus having: a roller for guiding a film coated with a resin; a first nitrogen gas introduction port and a second nitrogen gas introduction port for introducing nitrogen gas; a UV irradiation portion for irradiating the film with ultraviolet rays from between the first nitrogen gas introduction port and the second nitrogen gas introduction port; an oxygen concentration meter for measuring an oxygen concentration between the film and the UV irradiation portion; an air introduction port for introducing air between the film and the UV irradiation portion; and a controller for controlling at least any one of: an amount of air introduced from the air introduction port, an amount of nitrogen gas introduced from the first nitrogen gas introduction port, and an amount of nitrogen gas introduced from the second nitrogen gas introduction port, so that the oxygen concentration is within a preset oxygen concentration set range.