Xenon Flash Lamp Array for Homogeneous UV Curing

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Solution Overview

Problem

Existing curing devices for UV-curable fluids in the printing industry, particularly those using mercury vapor lamps, are costly and complex, and xenon flash lamps with glass tubes face challenges in achieving even irradiation across large formats due to their size and actuation complexity.

Innovation Solution

A device comprising multiple xenon flash lamps arranged in rows with adjustable power and orientation, allowing for even and homogeneous curing of UV-curable fluids on printing substrates, using pulsed discharges and energy storage to prevent inhomogeneous curing and damage, with the option to operate some lamps in cyclic and continuous modes for optimal curing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a single format-width xenon flash lamp is used, then the optical power is high enough for curing, but the actuation complexity and installation space increase significantly

Engineering Contradiction:

Improveoptical powerVSAvoidactuation complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The single format-width flash lamp is divided into multiple smaller flash lamps arranged in a row. Each smaller lamp can be actuated independently or in groups, reducing the overall actuation complexity while maintaining the total optical power needed for curing across the entire substrate width.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If periodic flashes are used by a single flash lamp, then the device is simpler, but varying degrees of irradiation occur across different areas of the substrate

Engineering Contradiction:

Improvedevice simplicityVSAvoidcuring uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Multiple flash lamps positioned across the substrate width allow different regions to be irradiated simultaneously or sequentially with controlled timing, ensuring uniform curing across the entire surface while avoiding the irradiation variations that occur with a single periodic flash source.

Inventive Principle:

Principle #1Segmentation

3Reliability

If mercury vapor lamps are used for final curing, then the curing effectiveness is high, but the cost and environmental impact increase

Engineering Contradiction:

Improvecuring effectivenessVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces expensive and environmentally harmful mercury vapor lamps with shorter-lived but mercury-free LED lamps. While LEDs have shorter operational lifetimes, they eliminate mercury contamination risks and reduce environmental impact, making them a more sustainable choice despite requiring replacement more frequently.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Productivity

If high intensity UV radiation is applied to cure the fluid quickly, then the curing speed increases, but the substrate may be damaged or curing becomes inhomogeneous

Engineering Contradiction:

Improvecuring speedVSAvoidsubstrate damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The curing process is divided into multiple stages using different numbers of flash lamps. Initially, only certain lamps are activated to provide gentle curing, and subsequently, additional lamps are activated to complete the curing process. This staged approach prevents substrate damage from excessive intensity while maintaining overall curing speed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flash lamps are operated in periodic pulses rather than continuous operation. This allows brief intervals between irradiation bursts, preventing overheating and damage to the substrate while still achieving rapid curing through repeated high-intensity pulses.

Inventive Principle:

Principle #19Periodic action

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 low-cost, environmentally friendly, and even/homogeneous curing of UV-curable printing fluids, adaptable to various substrate formats and speeds, reducing complexity and operational costs while ensuring uniform curing across the substrate.

Implementation Method 1

Xenon flash lamps are suitable for curing radically-curing color systems because such lamps have a wide emission spectrum including proportions of UV-A to UV-C radiation

Methodology Applied

Scientific EffectElectromagnetic radiation emission: Light

Implementation Method 2

the fluid, i.e., at least the polymerizable portion thereof, is polymerized

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 3

A flash lamp is preferably a gas discharge lamp which does not have continuous gas discharges but short pulsed discharges

Methodology Applied

Scientific EffectGas discharge: Electric Arc

Data Source

PatentUS12194729B2Device for curing a UV-curable fluid on a printing substrate by an emitter

Publication Date: 2025.01.14 HEIDELBERGER DRUCKMASCHINEN AG

AI summary

A device cures a UV-curable fluid, such as offset or inkjet printing ink, on a substrate by way of an emitter. The emitter includes at least two flash lamps which are disposed in a row. This provides a cost-efficient way of evenly and homogeneously curing UV-curable printing fluids at low environmental impact. There is also described a printing machine with a device for curing UV-curable printing ink.