UV-IR Laser Polymerization Device for Rapid Curing
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Solution Overview
Problem
Conventional UV-curable plastic polymerization devices using discharge lamps are inefficient in terms of energy usage and size, with laser sources being too large and expensive for effective curing.
Innovation Solution
A device combining a solid-state UV laser and an IR radiator to enhance polymerization speed by locally increasing temperature, using line-shaped radiation patterns for efficient energy delivery and controlled intensity ratios, with diode lasers for cost-effective and precise energy application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If discharge lamps are used for UV curing, then UV radiation can be provided, but energy efficiency is poor and device size becomes large
Solution Approach 1:
The patent replaces conventional discharge lamps with a solid-state laser system that uses a diode pump laser to excite a UV-emitting crystal. This substitution of the light generation mechanism achieves compact size while maintaining UV curing capability, directly resolving the contradiction between device size and UV radiation provision.
Solution Approach 2:
The patent changes the operating parameters by using a diode-pumped solid-state laser system that operates at specific wavelengths (e.g., 266 nm for UV). This parameter optimization allows the system to achieve high UV output with low energy consumption and compact dimensions, addressing both energy efficiency and size constraints.
2Productivity
If UV radiation alone is used for polymerization, then curing can be achieved, but polymerization speed is limited
Solution Approach 1:
The patent combines UV radiation from the solid-state laser with IR radiation from a separate IR source to simultaneously initiate and accelerate the polymerization process. This merging of two radiation types achieves faster curing speeds while maintaining energy efficiency, as the IR component provides thermal acceleration without requiring additional UV energy.
Solution Approach 2:
The patent creates a composite radiation field combining UV and IR components to act on the polymerizable material. This composite approach leverages the complementary effects of UV (initiation) and IR (thermal acceleration) to achieve superior polymerization speed and energy efficiency compared to UV alone.
3Temperature
If conventional IR emitter is used, then heating can be provided, but radiation field is not sharply delimited causing energy waste
Solution Approach 1:
The patent employs a diode laser as the IR source, which inherently produces a sharply delimited, focused beam. This local quality concentration ensures that IR energy is delivered precisely where needed on the polymerizable material, maximizing temperature increase efficiency while minimizing energy waste to surrounding areas.
Solution Approach 2:
The patent replaces conventional broad-area IR emitters with a diode laser system that uses optical focusing to concentrate IR energy. This substitution achieves sharp spatial delimitation of the heating zone, directly addressing the energy waste problem while maintaining effective local heating.
4Productivity
If high power UV laser is used, then curing speed increases, but device size and cost increase
Solution Approach 1:
The patent uses a diode-pumped solid-state laser system that achieves high UV power output in a compact form factor. The diode pump mechanism and crystal-based UV generation allow for high power density in a small volume, resolving the contradiction between curing speed and device size.
Solution Approach 2:
The patent optimizes the laser system parameters including pump diode power, crystal orientation, and optical cavity design to achieve maximum UV output power within minimal device volume. This parameter optimization enables high-power UV generation in a compact package, addressing both curing speed and size constraints.
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 achieves improved energy efficiency and curing speed with reduced size, allowing for high-energy, rapid polymerization of UV-curable plastics without damage, adaptable to various plastics and materials.
Implementation Method 1
A solid-state laser that emits in the UV range can be designed in such a way that it achieves the necessary power and still has a small size
Implementation Method 2
The temperature can be increased accordingly by the additional effect of IR radiation. With the help of an IR radiator, a very local increase in temperature can be brought about
Implementation Method 3
The UV radiation initiates and maintains the polymerisation process
Data Source
Figure 1
AI summary
The device for polymerizing ultraviolet curable plastics, comprises two different radiation sources for ultraviolet radiation and infrared radiation to which radiation the plastic to be cured is exposed. The radiation source for the UV radiation has a solid-state laser. The solid-state laser and the IR radiation source produce a linear radiation image on the plastic to be cured. The IR radiation source has a diode laser. The ratio of the intensities of the UV radiation and the IR radiation is adjustable to each other. The device for polymerizing ultraviolet curable plastics, comprises two different radiation sources for ultraviolet radiation and infrared radiation to which radiation the plastic to be cured is exposed. The radiation source for the UV radiation has a solid-state laser. The solid-state laser and the IR radiation source produce a linear radiation image on the plastic to be cured. The IR radiation source has a diode laser. The ratio of the intensities of the UV radiation and the IR radiation is adjustable to each other. The UV radiation and the IR radiation are formed from laser ingot and are arranged one upon the other so that its radiation images are formed at the same line on the plastic to be cured.