UVLED Optical Fiber Curing with Dynamic Intensity Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ultraviolet curing devices for optical fiber coatings, such as those using mercury lamps, are inefficient due to high power consumption, heat generation, and inability to automatically adjust UV intensity with real-time drawing speed and coating conditions, leading to energy waste and inconsistent curing quality.
Innovation Solution
A light intensity adjustable ultraviolet device featuring a UVLED light source module, cylindrical focusing lens, ultraviolet sensor, and semiconductor cooler, which forms a closed loop control system to adjust UV intensity based on optical fiber drawing speed, ensuring optimal curing and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If high-pressure mercury lamp is used to generate ultraviolet radiation, then ultraviolet intensity is sufficient for curing, but power consumption is very high (50kw for single coating layer)
Solution Approach 1:
The patent changes the fundamental parameter of the light source from mercury lamp to UVLED, transforming the mechanism of ultraviolet generation from gas discharge to electroluminescence. This parameter change results in dramatically reduced power consumption while maintaining sufficient ultraviolet intensity for curing optical fiber coatings
Solution Approach 2:
The patent replaces the mechanical/electrical discharge system of mercury lamps with a solid-state UVLED system. This substitution eliminates the need for high-power electrical discharge through mercury vapor, achieving the same curing function with much lower energy input
2Illumination intensity
If high-pressure mercury lamp is used to generate ultraviolet radiation, then ultraviolet curing is achieved, but large amount of heat energy is emitted instead of ultraviolet light, resulting in low energy utilization rate
Solution Approach 1:
The patent changes the emission spectrum parameter of the light source by using UVLEDs that emit primarily in the ultraviolet range (380-405nm) with minimal infrared radiation. This parameter change ensures that most of the electrical energy is converted to useful ultraviolet radiation rather than waste heat
Solution Approach 2:
The patent converts the inherent limitation of mercury lamps (low energy efficiency and excessive heat emission) into an advantage by selecting UVLEDs whose natural emission characteristics align with the curing wavelength requirements, thereby minimizing heat generation and maximizing ultraviolet output efficiency
3Illumination intensity
If high-pressure mercury lamp is used, then ultraviolet curing is achieved, but device overheating occurs requiring cooling systems
Solution Approach 1:
The patent changes the thermal emission parameter of the light source by using UVLEDs that operate at much lower temperatures compared to mercury lamps. This parameter change eliminates the need for complex cooling systems while maintaining effective ultraviolet curing
4Device complexity
If fixed ultraviolet intensity is used, then curing process is simple, but cannot adapt to different drawing speeds and coating conditions, resulting in inconsistent curing quality
Solution Approach 1:
The patent introduces a feedback control mechanism where the drawing speed signal is used to dynamically adjust the UVLED intensity. This feedback loop ensures that the ultraviolet intensity automatically adapts to different operating conditions, maintaining consistent curing quality across varying production speeds
Solution Approach 2:
The patent transforms the static ultraviolet intensity into a dynamic parameter that can be adjusted in real-time based on drawing speed and coating conditions. This dynamic adjustment capability allows the system to optimize curing quality for each specific operating condition without increasing overall system complexity
5Use of energy by moving object
If UVLED is used to replace mercury lamp, then energy consumption is reduced and heat generation is minimized, but UV intensity may be insufficient for high-speed curing
Solution Approach 1:
The patent merges multiple UVLEDs into an array configuration to achieve the required ultraviolet intensity. By combining the output of multiple individual UVLEDs, the system attains sufficient curing power for high-speed applications while maintaining the energy efficiency advantages of UVLED technology
Solution Approach 2:
The patent employs dynamic intensity adjustment of the UVLED array to match the drawing speed. At higher drawing speeds, the system increases UVLED intensity to maintain adequate curing, while at lower speeds it reduces intensity to conserve energy, thereby resolving the apparent contradiction between intensity and energy consumption
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 provides high curing efficiency, low energy consumption, and improved coating quality by automatically adjusting UV intensity in real-time, extending the service life of the UVLED light source and reducing heat generation.
Implementation Method 1
as a UV radiation source, a UVLED has advantages such as higher energy efficiency
Implementation Method 2
UV curing of an optical fiber coating refers to triggering quick polymerization and crosslinking of liquid-state coating materials on optical fibers by using ultraviolet light
Implementation Method 3
a cylindrical focusing lens configured in front of a light emitting surface of the UVLED light source module, so that ultraviolet light emitted by the UVLED light source module is focused on a curing axis
Implementation Method 4
A light source of the optical fiber coating curing device has a long service life, a less heating value, and low energy consumption
Data Source
Figure 1
Figure 2
AI summary
A light intensity adjustable ultraviolet device for curing an optical fiber coating includes a cylindrical mounting base; a UVLED light source module mounted along a peripheral direction and an axial direction in an inner cavity of the cylindrical mounting base; a cylindrical focusing lens configured in front of a light emitting surface of the UVLED light source module, so that ultraviolet light emitted by the UVLED light source module is focused on a curing axis; and an ultraviolet sensor mounted in the inner cavity of the cylindrical mounting base, wherein the ultraviolet sensor is connected to a UVLED power supply control module via an ultraviolet intensity signal processing module; the UVLED power supply control module is connected to the UVLED light source module, so that an optical fiber drawing speed and an ultraviolet intensity form a control closed loop.