Wavelength Conversion Element for UV Adhesive Bonding

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Solution Overview

Problem

Existing methods for bonding optical encoder components using ultraviolet-curable adhesives face challenges in curing the adhesive when one or both components are made of non-transmissive materials, as conventional methods rely on direct ultraviolet ray transmission, which is insufficient for materials that do not allow UV penetration.

Innovation Solution

Incorporating a wavelength conversion element that converts X-rays or high-transmittance energy rays into ultraviolet to blue light, allowing the adhesive to cure even when one component is made of non-transmissive materials by using a phosphor that emits curing light after being irradiated with X-rays or high-transmittance energy rays.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If ultraviolet-curable adhesive is used to bond components, then bonding strength is improved, but curing is impossible when components are made of non-transmissive materials

Engineering Contradiction:

Improvebonding strengthVSAvoidcuring feasibility

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

A wavelength conversion element (phosphor) is introduced as an intermediary between the X-ray source and the UV-curable adhesive. The phosphor converts X-ray energy into UV light, enabling the adhesive to cure through components that block direct UV transmission. This mediator resolves the contradiction by providing an alternative energy conversion pathway that bypasses the transmissivity limitation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the wavelength parameter of the curing radiation from ultraviolet to X-ray range. By using X-rays that can penetrate non-transmissive materials and then converting them to UV light at the target location, the system overcomes the material transmissivity barrier while maintaining the effectiveness of UV-curable adhesive bonding.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If direct ultraviolet ray transmission is used for curing, then curing efficiency is improved, but application is limited to transmissive materials only

Engineering Contradiction:

Improvecuring efficiencyVSAvoidmaterial compatibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The wavelength conversion element acts as a mediator that receives X-ray energy and converts it to UV light locally. This approach maintains high curing efficiency by using the highly penetrating X-rays for energy delivery while generating the required UV light exactly where needed, thus expanding material compatibility without sacrificing productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention replaces the direct UV optical transmission mechanism with an X-ray energy conversion mechanism. This substitution allows the system to work with non-transmissive materials by using a different portion of the electromagnetic spectrum that can penetrate the materials, then converting to UV at the bonding interface.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If wavelength conversion element is added to enable curing through non-transmissive materials, then material selection flexibility is improved, but device complexity increases

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidbonding system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

While the wavelength conversion element does add a component, it enables the use of high-performance non-transmissive materials like polyetherimide resin. The added complexity is justified by the significant gain in material selection flexibility and the ability to achieve bonds that would otherwise be impossible with conventional UV curing methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method ensures complete curing of the adhesive between components, including those made of non-transmissive materials, without the need for direct UV ray guidance, enhancing the bonding strength and allowing for the use of materials like polyetherimide resin, which improves environmental and mechanical properties.

Implementation Method 1

Methodology Applied

Scientific EffectPhosphorescence: Phosphorescence

Implementation Method 2

An ultraviolet-curable adhesive (to be abbreviated as a UV adhesive hereinafter) cured by irradiation with ultraviolet rays is commonly used to bond several components to each other

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS10207457B2Method for bonding components by using energy ray-curable adhesive

Publication Date: 2019.02.19 FANUC LTD

AI summary

A method for bonding components to each other according to this invention bonds, to a plate-shaped member or a shaft, an ultraviolet-curable adhesive cured by irradiation with ultraviolet rays and a wavelength conversion element which emits ultraviolet rays by irradiation with X-rays. The plate-shaped member is brought into contact with the shaft through a bonding layer formed by the ultraviolet-curable adhesive and the wavelength conversion element. The X-rays are transmitted through the plate-shaped member or the shaft to the bonding layer located between the plate-shaped member and the shaft to cure the ultraviolet-curable adhesive.