Movable UV Lamp Trolley for Compact Dosage-Controlled Curing
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Solution Overview
Problem
Existing UV curing systems require large ovens, expose substrates to excessive heat, and lack control over UV dosage independent of conveyor speed, leading to inefficiencies and potential substrate damage.
Innovation Solution
A UV oven with a movable UV lamp carriage system and programmable actuators allows for variable UV dosage control and reduced oven size by enabling independent movement of UV lamps relative to the substrate, using a trolley system to minimize energy consumption and accommodate varying coating thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed UV source is used with a conveyor moving the substrate, then the UV curing process is simple, but the oven size becomes large and UV dosage control is coupled with conveyor speed
Solution Approach 1:
The UV lamp assembly is made movable instead of fixed, allowing it to traverse back and forth over the substrate. This dynamic positioning enables the same UV dosage to be delivered in a compact space by repeatedly exposing the substrate to the UV source during multiple passes, eliminating the need for a large fixed oven structure.
Solution Approach 2:
The UV lamp performs periodic back-and-forth passes over the substrate rather than continuous exposure. This periodic action allows the UV source to cover the entire substrate area through multiple traverses, achieving complete curing in a compact oven while maintaining simple system operation.
2Manufacturing precision
If the substrate moves slowly through the UV irradiated area to achieve higher UV dosage, then the UV curing is more thorough, but the substrate overheats
Solution Approach 1:
Instead of moving the substrate slowly through a fixed UV source, the invention inverts the approach by moving the UV source back and forth over the substrate. This allows rapid substrate conveyance while the UV lamp performs multiple passes, achieving high UV dosage without prolonged heat exposure that would cause overheating.
Solution Approach 2:
The UV lamp assembly is made movable instead of fixed, allowing it to traverse back and forth over the substrate. This dynamic positioning enables the same UV dosage to be delivered in a compact space by repeatedly exposing the substrate to the UV source during multiple passes, eliminating the need for a large fixed oven structure.
3Device complexity
If a fixed UV lamp system is used, then the system structure is simple, but UV dosage cannot be controlled independently of conveyor speed
Solution Approach 1:
The UV lamp assembly is made movable instead of fixed, allowing it to traverse back and forth over the substrate. This dynamic positioning enables the same UV dosage to be delivered in a compact space by repeatedly exposing the substrate to the UV source during multiple passes, eliminating the need for a large fixed oven structure.
Solution Approach 2:
The system incorporates sensors that detect substrate position and conveyance speed, providing feedback to the control system. This feedback mechanism allows the UV lamp's movement and operation to be adjusted independently of conveyor speed, enabling precise UV dosage control through programmable pass patterns and duration regardless of how fast the substrate moves.
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 system achieves efficient UV curing with controlled dosage, reduced oven size, and energy savings while preventing substrate overheating, allowing for faster curing cycles and longer lamp life.
Implementation Method 1
at least one UV lamp supported within the housing by a carriage that is movable with respect to the housing
Implementation Method 2
UV curing system with UV lamp trolley system... UV light may be used to cure materials on a substrate
Data Source
Figure 1A~1D
Figure 2~3
Figure 4~5
AI summary
A UV oven for curing an applied coating on a part, includes a housing having a top wall, a bottom wall, and side walls that enclose an interior volume of the housing. The UV oven further includes a first shutter and a second shutter located on the side walls and configured to be selectively opened to selectively allow the part to enter or exit the interior volume of the housing. The UV oven further includes a conveyor secured to the housing and having a surface on which the part may be supported and at least one UV lamp supported within the housing by a carriage that is movable with respect to the housing. A method of curing an applied coating on a part is further disclosed.