Fudan University developed a new UV LED curing system, only the traditional 1/5 energy consumption

Only 1/5 of the original energy consumption, will be able to complete a technology breakthrough to achieve high speed fiber production half - by Fudan University electric light Research Institute deputy director, School of information science and engineering professor Zhang Shanduan and his team developed a fiber drawing tower with high efficiency ultraviolet light curing system LED. The UV LED curing system will be unveiled at the eighteenth China International Industry fair. Most of the UV curable ink through the system irradiation, just a few seconds to cure. Such a high power density, low energy consumption of innovative technology will enable the rapid development of optical fiber manufacturing industry.

Beyond the traditional energy consumption of 1/5 to achieve half the radiation intensity

The most prominent advantage of UV LED curing system is low energy consumption. High energy consumption compared with the traditional microwave medium pressure mercury lamp at 6000 watts, the line source is composed of ultraviolet LED only consumes 1200 watts, saving 80% energy consumption.

High efficiency ultraviolet LED light curing system with optical fiber drawing tower

Microwave medium pressure mercury lamp is used in the past for curing the optical fiber drawing tower. In the process of manufacturing optical fiber, when the optical fiber is pulled into filaments, the need to be coated on its surface of a protective nature of the ink material and curing, in general is to make the coating from liquid to solid. Printing, automotive, electronics, furniture and other industries, have this link. UV curing is the most common fast curing process, and the UV sensitive coatings can be cured by the corresponding light source irradiation.

However, there are many disadvantages in the traditional medium pressure mercury lamp, which can not only consume a lot of energy, but also produce a large amount of heat and radiation efficiency. According to the spectrum, the medium pressure mercury lamp emitted in the light of the curing of UV light is only about 10%, visible light of 20%, calorific value of up to 70%. Its curing efficiency is difficult to meet the growing demand of the optical fiber industry, but also contrary to the concept of economic and environmental protection.

The Zhang Shanduan team for using the LED light source developed a more efficient UV curing system, in addition to reduce energy consumption, the traditional equipment only 6000 hours of life, this system will be used to extend the life of 30000 hours. After more than a year of continuous operation, almost no light, photoelectric parameters remain factory condition. According to the spectrum, UV LED in the 365 to 385 nm for the curing of optical fiber ink, energy is very concentrated, compared to medium pressure mercury lamp, more favorable for curing. Zhang Shanduan said: the new UV LED curing system requires only 1/5 of the traditional energy consumption, you can achieve a doubling of radiation intensity than the traditional, drawing speed increased by half, and work longer. "

Leading international LED power density global first

According to reports, this UV LED UV curing system can not only completely replace the traditional microwave medium pressure mercury lamp, compared with the existing similar products, in many ways to achieve a breakthrough in technology and innovation.

The system is composed of three parts: optical fiber curing furnace, driving power supply and cooling system, and the optical fiber curing furnace is the core of the technology, and the LED light source is the key part of the whole system. Three years ago the Expo debut, LED UV light curing system developed by the Zhang Shanduan team, ultraviolet LED light source that can achieve 200 watts per square centimeter of the power density, has reached world leading level. This year for the optical fiber drawing tower UV LED curing system has been the highest packaging power density increased to 700 watts per square centimeter, stabilized the world's first technical position.

The industry can only be common ultraviolet LED chip to the highest 1 ampere current density per square millimeter, by LED chip Zhang Shanduan specially designed custom will be the bearing cap is increased to 4.5 amperes per square millimeter, which is mainly due to its packaging technology innovation.

Another highlight of the technological innovation is the highly efficient UV refractive and reflective systems. This optical system includes a careful design of the lens and the reflector can be ultraviolet light emitted from the convergence to the cylindrical axis, the axis of the radiation intensity enhancement, reduce optical loss, thereby improving the curing speed of drawing.

Boost production in the future is expected to promote more changes in the industry

At present, the system has declared 6 invention patents, excellent technical performance has also produced significant economic and social benefits.

Under the help of the system, to maintain the same system input power, the optical fiber drawing tower drawing speed can be increased by nearly 50%, reaching an astonishing speed of 3000 meters per minute. At present, only two drawing towers can be used to obtain the output of the original three drawing towers, which can save investment, increase production and reduce energy consumption.

Data show that several international giants in the small scale fiber after using the system, nearly three years a total added value of 1 billion 840 million yuan, the new profit of 300 million yuan, and saving 4 million 20 thousand kwh, electricity saving benefit discount 4 million 430 thousand yuan, 4 thousand tons of carbon dioxide emissions. Therefore, this set of optical fiber tower with UV LED curing system for the production of optical fiber industry is a major breakthrough, will effectively promote the renovation of UV curing equipment. Zhang Shanduan is confident that within three years to achieve the domestic enterprise fiber curing furnace technology upgrade. In the future, the technology is also expected to be used in more areas related to light curing, such as printing, wood flooring, home, flooring and other industries. For paint, wood, printing and other types of light curing, the