UVLED Curing Apparatus for Optical Fiber Coatings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mercury lamps used for UV curing of glass-fiber coatings are inefficient, consuming significant power, generating excessive heat, and wasting energy due to a wide spectrum of electromagnetic radiation, with much of the UV radiation not reaching the small glass fibers.
Innovation Solution
A UVLED apparatus with UVLED-mirror pairs is used to emit and reflect UV radiation efficiently onto the glass fibers, reducing power consumption and heat generation while focusing UV radiation onto the fibers for effective curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mercury lamps are used to generate UV radiation for curing, then UV radiation intensity is sufficient, but power consumption is high and heat generation is excessive
Solution Approach 1:
The patent extracts only the useful UV radiation wavelengths (300-400 nm) from the electromagnetic spectrum by using UVLEDs that emit primarily in this range, eliminating the waste of energy on other wavelengths produced by mercury lamps. This selective extraction of useful radiation achieves sufficient UV intensity while dramatically reducing power consumption.
Solution Approach 2:
The patent changes the fundamental parameter of radiation generation from broad-spectrum mercury lamp emission to narrow-spectrum UVLED emission. By changing the wavelength distribution parameter to concentrate energy in the 300-400 nm range, the system achieves high UV intensity with much lower power consumption and reduced heat generation.
2Reliability
If mercury lamps are used to generate UV radiation, then curing can be achieved, but much of the energy is emitted as heat requiring cooling
Solution Approach 1:
The patent converts the harmful broad-spectrum radiation and heat waste of mercury lamps into a benefit by using UVLEDs that naturally emit only in the useful UV range. The energy that would have been wasted as heat or non-UV radiation is instead concentrated into effective UV wavelengths, eliminating the need for cooling systems while maintaining reliable curing capability.
3Manufacturing precision
If mercury lamps emit wide spectrum radiation, then some UV radiation reaches the fiber, but most radiation is wasted not reaching the small glass fiber
Solution Approach 1:
The patent applies local quality by positioning multiple UVLEDs in close proximity to the glass fiber surface, creating highly localized UV radiation zones directly where curing is needed. This localized approach ensures that UV energy is delivered precisely to the fiber coating rather than being wasted in broad-spectrum radiation that misses the small fiber target.
Solution Approach 2:
The patent transitions from the broad spatial distribution of mercury lamp radiation to a concentrated, multi-point UVLED arrangement surrounding the fiber. By changing the dimensional arrangement to multiple close-spaced LED sources, the system achieves comprehensive UV coverage of the fiber surface with minimal energy waste.
4Productivity
If higher intensity UV radiation is used to reduce curing time, then production rate increases, but power consumption increases
Solution Approach 1:
The patent replaces the mechanical/thermal curing approach with a photonic approach using UVLEDs. The substitution of LED technology provides high-intensity UV radiation with much lower power consumption compared to traditional mercury lamps, enabling increased production rates without proportional increases in energy use.
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 UVLED apparatus achieves improved curing efficiency by focusing UV radiation onto the glass fibers, reducing energy waste and increasing production line speeds with lower heat generation and power consumption.
Implementation Method 1
employ one or more UVLEDs that emit electromagnetic radiation
Implementation Method 2
A glass fiber having an incompletely cured coating is passed through the curing space to effect the absorption of both emitted and reflected UV radiation, thereby curing the coated glass fiber
Implementation Method 3
At least some of the UV radiation transmitted entirely through the curing space is reflected toward the curing space (e.g., with a mirror)
Implementation Method 4
A glass fiber having an incompletely cured coating is passed through the curing space to effect the absorption of both emitted and reflected UV radiation
Data Source
AI summary
A UVLED apparatus and method provide efficient curing of an optical-fiber coating onto a drawn glass fiber. The apparatus and method employ one or more UVLEDs that emit electromagnetic radiation into a curing space. An incompletely cured optical-fiber coating, which is formed upon a glass fiber, absorbs emitted and reflected electromagnetic radiation to effect improved curing.