UV LED Curing Assembly with Reflector and Lens
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Solution Overview
Problem
Existing UV curing systems face challenges with heat generation and radiation intensity distribution, particularly with mercury lamps and UV LEDs, where heat damage and insufficient radiation focus at larger substrate distances hinder efficient curing processes.
Innovation Solution
A curing assembly comprising an array of UV LEDs, an elongate reflective surface with a lens system, and a specific LED array pattern to enhance radiation focus and heat management, including a cylindrical or convergent lens and a reflective surface with two focal points, and a unique LED arrangement for improved packing density and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If UV LEDs are used as radiation source, then heat generation is reduced compared to mercury lamps, but radiation intensity at large gaps (50mm+) is insufficient
Solution Approach 1:
The LED array is divided into multiple individual LED elements arranged in a specific pattern, allowing each LED to contribute to radiation at different positions. This segmentation enables the system to achieve sufficient radiation intensity at large gaps by combining the output of multiple LEDs rather than relying on a single source
Solution Approach 2:
The patent introduces a lens system that focuses radiation from the LED array onto the substrate at a specific focal plane. This adds an optical dimension to the radiation delivery system, allowing the LEDs to be positioned at a distance from the substrate while still achieving high radiation intensity through focal convergence
2Illumination intensity
If a reflector is used with UV LEDs, then radiation focus is improved, but the system becomes more complex
Solution Approach 1:
The patent combines the reflector and lens into a single integrated optical system where the reflector is positioned behind the lens. This merging of components achieves effective radiation focusing while minimizing the overall number of separate parts and simplifying the optical path
Solution Approach 2:
The lens acts as an intermediary element that receives diverging radiation from the LED array and converts it into a focused beam at the substrate position. This intermediary component enables the reflector to be positioned optimally for radiation collection without directly interfering with the focal geometry
3Ease of manufacture
If LEDs are arranged in a simple row with individual lenses, then manufacturing is simplified, but radiation intensity and focusing efficiency are insufficient
Solution Approach 1:
The LED array uses a specific pattern where LEDs are spaced differently in different regions - closer spacing in some areas and greater spacing in others. This local variation in LED arrangement optimizes radiation distribution and focusing efficiency for the specific application while maintaining manufacturability
Solution Approach 2:
The LED array pattern is asymmetric, with LEDs arranged more densely in certain regions and spaced apart in others, rather than using uniform spacing. This asymmetric arrangement creates optimal radiation distribution for the curing application while the overall structure remains simple enough for efficient manufacturing
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 solution enables efficient and intense UV radiation delivery over significant distances with reduced heat effects, improving curing efficiency and preventing substrate damage, while maintaining a compact and cost-effective optical system.
Implementation Method 1
a reflector with an elongate reflective surface partly surrounding the array and having an opening for emission of radiation towards a substrate
Implementation Method 2
a lens between the array and the opening... The lens is provided for these direct rays and preferably it and the reflective surface have a common focal point at the substrate support position
Implementation Method 3
at least one array of UV LEDs
Data Source
AI summary
A curing assembly for curing of inks and the like comprises at least one array of UV LEDs 18. A reflector 4 with an elongate reflective surface 14 partly surrounds the array 18 and has an opening for emission of radiation towards a substrate. A lens 24 is positioned between the array 18 and the opening.