UV Mask Device Using LED Array for Display Curing
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Solution Overview
Problem
Conventional UV light sources, such as mercury lamps and metal halide lamps, suffer from issues like mixed wavelengths causing light loss and instability, contain harmful substances like ozone and heavy metals, and generate excessive heat, leading to contamination and inefficient light utilization in display panel fabrication processes.
Innovation Solution
The use of a UV mask device with a light source array composed of UV LEDs emitting light at specific single central wavelengths, arranged to optimize distribution density and reduce heat generation, along with a cooling system to enhance heat dissipation and improve light utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional UV light sources (mercury lamps, metal halide lamps) are used, then high UV light output is achieved, but mixed wavelengths cause light loss and instability
Solution Approach 1:
The patent segments the UV light source into multiple discrete wavelength components using an array of UV LEDs, each emitting at a specific wavelength. This segmentation allows selective use of only the wavelengths needed for the photopolymerization reaction, eliminating light loss from unnecessary wavelengths while maintaining high UV output intensity.
Solution Approach 2:
The patent applies local quality by matching specific UV LED wavelengths to the absorption characteristics of the photopolymerizable group in the resin. Each region of the light source array is configured with LEDs whose wavelengths correspond to the absorption peaks of the material, ensuring maximum light utilization efficiency and eliminating energy loss from mismatched wavelengths.
2Illumination intensity
If conventional UV light sources are used, then sufficient UV irradiation is provided, but harmful substances like ozone and heavy metals are generated
Solution Approach 1:
The patent extracts and eliminates harmful substances by replacing conventional UV light sources (mercury lamps and metal halide lamps) with UV LED arrays. This substitution removes the sources of ozone generation and heavy metal contamination while maintaining sufficient UV irradiation intensity for photopolymerization, thereby eliminating harmful byproducts.
Solution Approach 2:
The patent converts the harmful broad-spectrum UV radiation from conventional sources into beneficial monochromatic or narrow-band UV radiation from LEDs. This transformation eliminates harmful wavelengths that produce ozone and heavy metal emissions while concentrating the UV energy at wavelengths optimal for photopolymerization, turning a harmful process into a clean and efficient one.
3Illumination intensity
If conventional UV light sources are used, then UV exposure is achieved, but excessive heat is generated causing contamination
Solution Approach 1:
The patent replaces the thermal-mechanical UV light generation process of conventional lamps with a solid-state LED-based optical system. UV LEDs generate UV light through electroluminescence rather than thermal radiation, dramatically reducing heat generation while maintaining sufficient UV exposure intensity for photopolymerization, thus eliminating heat-induced contamination.
4Productivity
If conventional UV light sources are used, then UV curing is performed, but light utilization efficiency is low
Solution Approach 1:
The patent changes the wavelength parameter of the UV light source to match the absorption characteristics of the photopolymerizable material. By selecting UV LED wavelengths that correspond to the absorption peaks of the photopolymerizable group, the system maximizes light absorption and polymerization efficiency, thereby improving productivity and eliminating energy loss from non-absorbed wavelengths.
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 solution reduces light loss, increases light utilization, and ensures stable chemical reactions and fabrication processes by using UV LEDs that emit light at targeted wavelengths, minimizing environmental and health hazards while providing better adhesion and reaction rates compared to conventional UV light sources.
Implementation Method 1
a light source array, configured above the mask substrate by a first distance and including a plurality of UV light-emitting diodes (UV LEDs) emitting light with a first single central wavelength
Implementation Method 2
the first single central wavelength corresponds to an absorption wavelength of the material to be cured
Data Source
AI summary
The present application discloses an ultraviolet (UV) mask device and a method for using the UV mask device. The UV mask device includes: a platform, configured for carrying a substrate thereon; a mask substrate, configured above the platform for fixing a mask corresponding to the substrate on the platform; and a light source array, configured above the mask substrate by a first distance and including a plurality of UV light-emitting diodes (UV LEDs) emitting light having a first single central wavelength.