UV Lamp Mount Airflow Channel for Cooling
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Solution Overview
Problem
Existing lamp assemblies for UV curing in the printing and coating industry face issues with radiation reflection back onto the lamp, leading to heating and distortion, and require complex cooling systems, especially with increasing lamp powers, which are costly and inefficient, particularly in air-cooled systems where easy lamp replacement is difficult.
Innovation Solution
A lamp assembly with a mount that guides air flow around the radiation source, enhancing cooling efficiency and allowing for easy lamp replacement by securing the radiation source with end pieces and a channel for air extraction, and using support members to maintain accurate positioning relative to the reflector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water cooling is used to cool the lamp, then cooling efficiency is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses air cooling instead of water cooling by providing a cooling air flow path through the reflector structure. Cooling air is introduced into the reflector cavity and flows around the lamp to remove heat, eliminating the need for water tubes, pumps, and complex hydraulic systems while achieving effective cooling of high-power UV lamps
2Device complexity
If air cooling is used to cool the lamp, then device complexity is reduced, but cooling efficiency deteriorates
Solution Approach 1:
The reflector is divided into multiple sections with dedicated cooling air flow paths. Each section has its own air inlet and flow channel, allowing segmented cooling of different lamp regions. This segmentation enables efficient heat removal from high-power lamps using simple air cooling by creating multiple independent cooling zones throughout the reflector structure
Solution Approach 2:
The patent introduces cooling air flow in multiple dimensions within the reflector cavity. Cooling air flows not only axially but also radially and in cross-flow patterns, creating a three-dimensional cooling network that maximizes heat removal efficiency from the lamp surface using only air cooling
3Productivity
If lamp power is increased to increase curing speed, then productivity is improved, but lamp heating and distortion increase
Solution Approach 1:
The reflector structure is pre-designed with integrated cooling air flow paths and heat dissipation features before the lamp operates. Cooling air inlets and flow channels are built into the reflector geometry, so that when high-power lamps are installed, cooling is immediately effective from startup, preventing temperature buildup that would cause distortion or reduce lamp life
Solution Approach 2:
The patent converts the waste heat generated by high-power UV lamps from a harmful effect into a controlled thermal management opportunity. By designing the reflector to channel cooling air directly over the hottest lamp regions, the system uses the temperature gradient created by high-power operation to drive natural convection currents that enhance cooling efficiency, allowing sustained high-power operation without distortion
4Temperature
If complex cooling systems are used to cool the lamp, then lamp temperature control is improved, but ease of operation deteriorates
Solution Approach 1:
The lamp assembly is segmented from the cooling system. The lamp can be removed and replaced independently without disconnecting or reconfiguring cooling air tubes, pumps, or water connections. The reflector's integrated cooling structure remains in place, allowing rapid lamp changes while maintaining continuous cooling operation
Solution Approach 2:
The cooling system is designed to automatically continue operating without intervention during lamp replacement. Cooling air flow paths are maintained by the fixed reflector structure, and the system self-regulates cooling continuity, eliminating the need for operators to shut down or reconfigure cooling systems when changing lamps
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 design improves air flow over the lamp, increasing cooling and lamp efficiency, prolonging lamp life, and allows for quick and easy lamp replacement without disassembling the entire assembly, while maintaining efficient cooling and preventing overheating.
Implementation Method 1
the mount shaped for directing air drawn towards the mount to cause the air to flow around at least part of the radiation source and between the radiation source and the mount
Implementation Method 2
provide each lamp in an assembly with a reflector which includes a reflective surface partly surrounding the lamp for reflecting radiation therefrom onto the substrate
Data Source
AI summary
A lamp assembly includes an elongate source of radiation formed with end pieces and a mount connected to the end pieces for securing the radiation source in an irradiator. The mount is shaped for directing air drawn towards the mount to cause the air to flow around at least part of the radiation source and between the radiation source and the mount.