UV Lamp Trolley Curing Oven for Independent Dosage Control
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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 overheating and inefficient energy use.
Innovation Solution
A UV oven with movable UV lamps on a carriage system, controlled by a controller, allows for variable UV dosage and reduced oven size by moving lamps relative to the substrate, enabling precise UV exposure and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed UV source is used with a moving substrate, then the UV curing process is simple, but the oven size becomes large and excessive heat is generated
Solution Approach 1:
Instead of moving the substrate under a fixed UV source, the patent inverts the approach by keeping the substrate stationary and moving the UV lamp carriage over the substrate. This inversion allows for a compact oven design while maintaining effective UV curing coverage.
Solution Approach 2:
The patent employs a movable UV lamp carriage that can dynamically adjust its position and speed along the conveyor path. This dynamic system allows the UV dosage to be controlled independently of conveyor speed, enabling precise curing without requiring a large oven volume.
2Manufacturing precision
If the substrate moves slowly through the irradiated area to achieve higher UV dosage, then the UV curing is more thorough, but the substrate overheats
Solution Approach 1:
The movable UV lamp carriage allows independent control of UV dosage through variable speed adjustment of the carriage motor, separate from the conveyor speed. This enables thorough curing without requiring slow substrate movement, preventing overheating while maintaining manufacturing precision.
Solution Approach 2:
The system can implement periodic or variable speed cycles of the UV lamp carriage, adjusting the irradiation intensity and duration dynamically during the curing process to achieve optimal dosage without excessive heat accumulation.
3Device complexity
If a fixed UV lamp system is used, then the system structure is simple, but the UV dosage cannot be controlled independent of conveyor speed
Solution Approach 1:
The movable UV lamp carriage introduces a degree of freedom that decouples UV dosage control from conveyor speed. The carriage can be programmed to move at different speeds or pause at specific positions, providing adaptable UV dosage control while maintaining a relatively simple overall system structure.
4Object-affected harmful factors
If inlet and outlet shutters are included to protect operators, then operator safety is improved, but the required oven length increases
Solution Approach 1:
By inverting the traditional approach and moving the UV lamps rather than the substrate, the patent reduces the required oven length. The movable carriage system allows for more compact positioning of UV sources closer to the substrate, reducing the overall oven dimensions while still accommodating safety shutters.
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 by minimizing lamp usage to only what is necessary, while accommodating variable coating thicknesses and topographies.
Implementation Method 1
exposing the applied coating to UV light from at least one UV lamp
Implementation Method 2
UV curing a coating on a part
Data Source
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.