Fudan University has developed an efficient UV LED UV curing system to achieve LED power density in the world.

With only 1/5 of the energy consumption required, half of the fiber production speed can be achieved. A breakthrough in technology has been achieved by the high efficiency UV LED curable system developed by Zhang Shanduan, vice director of the Institute of electrical light research, Fudan University, Professor of information science and engineering, and his team. The UV LED curing system will soon be unveiled at the eighteenth China International Industry Fair. Most of the photocurable ink can be solidified in a few seconds after being irradiated by the system. Such innovative technologies with high power density and low energy consumption will make the optical fiber industry achieve rapid development. Beyond the traditional 1/5 of the energy consumption to achieve half of the radiation intensity UV LED UV curing system, the most prominent advantage is low energy consumption. Compared with the traditional microwave medium pressure mercury lamp, it can consume more than 6000 Watts at a high energy consumption. The line light source composed of ultraviolet LED only consumes 1200 watts, saving 80% energy consumption. The microwave medium pressure mercury lamp is a curing device used to be used in the optical fiber drawing tower. In the process of manufacturing optical fiber, when the optical fiber is drawn into filaments, a protective coating of ink material should be coated on its surface and solidified. Printing, automobile, electronics, furniture and other industries are indispensable. UV curing is the most common fast curing process. UV sensitive coatings can be cured after exposure to the corresponding light source. However, there are many disadvantages in the traditional microwave source, such as microwave medium pressure mercury lamp, not only for high energy consumption, but also for microwave magnetron. According to the spectrum, the light emitted from the medium pressure mercury lamp is only about 10% of the UV light that is useful for curing, and the visible light is 20% and the calorific value is 70%. Its curing efficiency is difficult to meet the growing demand of optical fiber industry, and it is contrary to the current concept of economic and environmental protection. The Zhang Shanduan team used UV LED light source to develop a more efficient UV curing system. In addition to reducing energy consumption, the traditional equipment has only 6000 hours of life, and the system will extend its service life to 30000 hours. After more than a year of continuous operation, almost no light decay, photoelectric parameters remain factory status. According to the spectrum, UV LED is very concentrated in the 365 to 385 nm wave band for curing ink. It is more beneficial to curing than the medium pressure mercury lamp. Zhang Shanduan said: "the new UV LED light curing system can achieve twice the radiation intensity of the traditional 1/5 energy consumption, and increase the wire drawing speed by half, and work longer." Leading international LED power density global first introduction, this UV LED UV curing system can not only completely replace the traditional microwave medium pressure mercury lamp, but also has achieved technical breakthroughs and innovations in many aspects compared with the existing similar products. The system is composed of three parts: fiber curing furnace, driving power supply and cooling system. The optical fiber curing furnace is the core of the technology, and the LED light source is the most critical part of the whole system. At the Expo three years ago, the UV LED UV curing system developed by the Zhang Shanduan team was first unveiled. At that time, the UV LED light source could achieve 200 watts per square centimeter of power density, and has reached the world's leading level. This year, the UV LED UV curing system for fiber optic towers has increased the maximum packaging power density to 700 watts per square centimeter, which has stabilized the world's first technology position. The most common ultraviolet LED chips in the industry can only withstand the current density of 1 amperes per square millimeter. The specially designed LED chip by Zhang Shanduan can increase the limit to 4.5 amperes per square millimeter, which is mainly due to its innovative packaging technology. Another highlight of technological innovation is the efficient ultraviolet refraction and reflection system. The optical system includes carefully designed lenses and reflectors, which can converge the ultraviolet light emitted by the light source to the axis of the cylinder, enhance the radiation intensity of the axis, reduce the optical loss, and improve the curing speed of the wire drawing. Boosting the future of production is expected to promote more industry changes. At present, the system has declared 6 invention patents, and remarkable technical performance has also produced remarkable economic and social benefits. With the help of the system, the same system input power can be maintained, and the drawing speed of the fiber drawing tower can increase by nearly 50%, reaching the astonishing speed of 3000 meters per minute. Nowadays, only two drawtowers can get the output of the original three wire drawing towers, which not only saves investment, but also increases production. At the same time, it can also reduce energy consumption. Data show that after the small scale use of the system, several international optical fiber giant enterprises have increased output value of 1 billion 840 million yuan in the past three years, with an additional profit of 300 million yuan, and 4 million 20 thousand kilowatt hours of electricity saving. The electricity saving benefit is 4 million 430 thousand yuan, and the carbon dioxide emission reduction is 4 thousand tons. Therefore, the UV LED UV curing system for this fiber drawing tower is a major breakthrough for the production of optical fiber industry, and will strongly promote the innovation of UV curing equipment. Zhang Shanduan is confident that within three years the upgrading of domestic fiber optic solidification furnace technology will be realized. In the future, the technology is expected to be applied to more areas related to light curing, such as printing, wood flooring, home furnishing, floor and other industries. For painting, wood, printing and other types of light curing, the technology can also save energy to 90%.