LED阵列型紫外固化光源的关键技术研究
摘要
紫外光固化技术是目前应用最为广泛的一种辐射固化技术。该技术一直是世界各国表面处理技术的研究重点之一,品种丰富、性能优良的UV新材料层出不穷;然而,同样影响固化效果的紫外固化光源发展相对缓慢,几种常用紫外光源在工业生产中日益暴露出缺点:高压汞灯需要高压驱动和冷却设备,耗电量高,辐照不均匀,可调性差,固化效率低,存在重金属污染:微波无电极紫外光源价格昂贵,与汞灯同样的灯管结构使得该光源应用也存在局限等;基于UV LED的点光源利用LED作为发光元件,具有许多良好的性能特点,但辐照面积等指标受到限制。本文对现有UV固化光源的应用情况进行了较为深入地调研,针对高压汞灯等光源使用中存在的问题,充分利用UV LED的优点,探索性地设计出一种辐照均匀稳定并且灵活可调的LED阵列型紫外固化光源系统,并实现一套3*3LED阵列的光源系统验证了系统方案的可行性。
在驱动单元设计方面,系统采用了以AT89S52为控制核心的多路可控恒流源系统,使各路LED的驱动电流通过外部按键独立可调,兼顾多种UV材料和不同固化对象形态的要求,调节方式分为粗调、细调两种;光学系统设计采用了单管准直系统与LED空间阵列结构相结合的光学处理方案。LED排布在弧面基板上组成空间阵列,沿同一弧线的LED发光经大数值孔径准直系统会聚于弧面轴线,得到一条光带用于固化,控制LED数量及工作电流可调节辐照面积及光源辐照度。本系统摒弃了传统光源“一刀切”的辐照现状,可灵活调节辐照面上光功率密度分布,使得三维物体的高效固化成为现实。
在完成设计和功能调试的基础上,用3*3LED阵列的实验系统对本文方案进行了一系列的实验验证,包括驱动单元的精度、稳定性以及光源辐照度可控性、均匀性等,实验数据分析表明驱动单元和光学系统均符合设计要求,光源工作时表现出良好的稳定性、均匀性和可调控性,验证了系统方案的性能指标。
UV curing becomes the most extensive radiation curing technology these days. This technology has been one of the main emphases in surface processing research all over the world, for what a great number of novel UV materials appear with excellent quality. In spite of that, the development of UV curing sources which affects the curing effect as UV materials is relatively slow, and serious shortcomings of several common UV curing sources have arisen in the industry application: high-pressure mercury lamp has many disadvantages such as high-pressure driven, cooling instrument needed, large power dissipation, uneven UV radiation, poor controllability, low curing efficiency, and heavy metal pollution; microwave UV source is high cost and its light structure as high-pressure mercury lamp limits the application; a kind of point source with UV LED has many adaptive characteristics although its radiation area doesn't meet some common demands. This thesis surveys the application condition of common UV curing sources and conducts an exploratory design on UV curing source with LED array, which will offer even, stable UV radiation and good controllability. A UV source system with 3*3 LED array is realized to verify the feasibility of the design.
In the drive part, multipath controllable constant current source based on AT89S52 is adopted, so each branch current can be controlled independently by the keys in two modes, which give attention to several UV materials and different base figures with coarse adjustment and fine adjustment; Optical design combines single LED's collimation system and LED spatial structure. LEDs assigned on the arc board compose the spatial structure, in which the radiation of LEDs on same arc line converges at the axis and a facula is available for curing. Radiation area and intensity are controlled by changing the number and drive current of LEDs. Different from other UV sources, optical power density on the curing object can be adjusted easily and flexibly, which make curing for 3D object come true.
On basis of design, the thesis conducts a series of experiments to verify the method using a system with 3*3 LED array, containing precision and stability of drive part and controllability and uniformity of the UV source. The results prove that drive part and optical system meet the design demand, and this UV source shows good stability, uniformity and controllability.
在驱动单元设计方面,系统采用了以AT89S52为控制核心的多路可控恒流源系统,使各路LED的驱动电流通过外部按键独立可调,兼顾多种UV材料和不同固化对象形态的要求,调节方式分为粗调、细调两种;光学系统设计采用了单管准直系统与LED空间阵列结构相结合的光学处理方案。LED排布在弧面基板上组成空间阵列,沿同一弧线的LED发光经大数值孔径准直系统会聚于弧面轴线,得到一条光带用于固化,控制LED数量及工作电流可调节辐照面积及光源辐照度。本系统摒弃了传统光源“一刀切”的辐照现状,可灵活调节辐照面上光功率密度分布,使得三维物体的高效固化成为现实。
在完成设计和功能调试的基础上,用3*3LED阵列的实验系统对本文方案进行了一系列的实验验证,包括驱动单元的精度、稳定性以及光源辐照度可控性、均匀性等,实验数据分析表明驱动单元和光学系统均符合设计要求,光源工作时表现出良好的稳定性、均匀性和可调控性,验证了系统方案的性能指标。
UV curing becomes the most extensive radiation curing technology these days. This technology has been one of the main emphases in surface processing research all over the world, for what a great number of novel UV materials appear with excellent quality. In spite of that, the development of UV curing sources which affects the curing effect as UV materials is relatively slow, and serious shortcomings of several common UV curing sources have arisen in the industry application: high-pressure mercury lamp has many disadvantages such as high-pressure driven, cooling instrument needed, large power dissipation, uneven UV radiation, poor controllability, low curing efficiency, and heavy metal pollution; microwave UV source is high cost and its light structure as high-pressure mercury lamp limits the application; a kind of point source with UV LED has many adaptive characteristics although its radiation area doesn't meet some common demands. This thesis surveys the application condition of common UV curing sources and conducts an exploratory design on UV curing source with LED array, which will offer even, stable UV radiation and good controllability. A UV source system with 3*3 LED array is realized to verify the feasibility of the design.
In the drive part, multipath controllable constant current source based on AT89S52 is adopted, so each branch current can be controlled independently by the keys in two modes, which give attention to several UV materials and different base figures with coarse adjustment and fine adjustment; Optical design combines single LED's collimation system and LED spatial structure. LEDs assigned on the arc board compose the spatial structure, in which the radiation of LEDs on same arc line converges at the axis and a facula is available for curing. Radiation area and intensity are controlled by changing the number and drive current of LEDs. Different from other UV sources, optical power density on the curing object can be adjusted easily and flexibly, which make curing for 3D object come true.
On basis of design, the thesis conducts a series of experiments to verify the method using a system with 3*3 LED array, containing precision and stability of drive part and controllability and uniformity of the UV source. The results prove that drive part and optical system meet the design demand, and this UV source shows good stability, uniformity and controllability.
引文
[1]吕延晓.辐射固化及其图文影像功能.中国感光学会第七次全国会员代表大会暨学术年会和第七届青年学术交流会论文摘要集:336-340.
[2]金养智.持续快速发展的中国光固化产业.精细与专用化学品,2004,12(20):3-6.
[3]王建国,滕人瑞.辐射固化——面向21世纪的绿色工业的新技术.原子核物理评论,2000,17(4):243-247.
[4]陈用烈,曾兆华,杨建文等.辐射固化材料及其应用.北京:化学工业出版社,2003.
[5]洪啸吟,金有铠,金养智.中国辐射固化技术发展.热固性树脂,2002,17(1):31-34.
[6]邹应全,张雅静.电子束(EB)固化技术应用大有前途.2005年中国科协学术年会论文集:90-92.
[7]朱胜武,施文芳.紫外光固化设备与光固化合物的研究.感光科学与光化学,2001,19(4):295-301.
[8]吕延晓.全球辐射固化市场动向.精细与专用化学品,2002,(23):7-9.
[9]www.ftachina.org 中国印刷技术协会,紫外线固化技术应用在柔性版印刷上
[10]Bob Goss.Bonding Glass and Other Substrates with UV Curing Adhesives.International Journal of Adhesion and Adhesives,2002,12(5):405-408.
[11]G.V.Shiryaeva,et al.Application of UV/EB cured coating to different substrates.Radiation physics and chemistry,1995(46):995-998.
[12]陈明,洪啸吟.紫外光固化涂料的进展.涂料工业,1999(12):30-36.
[13]王娟娟,马晓燕,晁小练.辐射固化技术研究进展.材料保护,2005,38(1):44-47.
[14]Synder D L.Electroplating nickel/chromium for automotive industry.Metal Finishing,1997(8):29-33
[15]洪啸吟.辐射固化涂料及进展.现代涂料及涂装创刊10周年特刊:8-12.
[16]张钟宪,周荫庄,郑建华等.“绿色”涂料——紫外固化涂料.首都师范大学学报(自然科学版),26(1):57-60.
[17]张强宇,肖新颜.国内紫外光固化涂料的发展及应用.合成材料老化及应用,2004,33(2):26-29.
[18]吕延晓.UV涂料与辐射固化.中国化工报,2005-4-19,006版.
[19]胡学梅,陈红梅,秦长喜等.UV固化涂料在石材上的应用.信息记录材料,2006,7(2):20-22.
[20]纪振鹏.UV油墨的性能及其应用.今日印刷,2006(4).
[21]金养智.紫外线固化技术在数字成像材料中的应用.影像技术,2006(1):8-11.
[22]Miller HC.UV/EB-Cure urethane acrylate and epoxy acrylate coating.Modern Paint and Coatings,1993(12):40.
[23]吕希光,马家举,江棂.辐射固化胶粘剂的应用与研究.中国胶粘剂,2004,13(5):55-59.
[24]杨冬梅,金燕.UV固化胶粘剂在液晶组装中的应用.粘接,2003,24(5):49-50.
[25]张丽华,陈军.紫外光固化胶粘剂的制备及性能研究.华北工学院学报,2003,24(2):131-134.
[26]景惧斌.紫外光固化粘合剂.信息记录材料,2004,5(4):31-36.
[27]黄广新.无处不在的辐射固化技术.信息记录材料,2001,2(2):47-49.
[28]洪啸吟.光固化汽车涂料.现代涂料与涂装,2004(1):32-36.
[29]www.ist-uv.de IST METZ GmbH Nürtingen,Oliver Starzmann,UV Curing Technology
[30]John Maitland.Microwave powered UV curing systems.Wire Industry,2003,70(831):168.
[31]王德海,江棂.紫外光固化材料——理论与应用.北京:科学出版社,2001.
[32]R.W.Stowe.Key Factors in the UV Curing Process-The Relationship of Exposure Conditions and Measurement in UV Process Design and Process Control-Part II:Lamp Systems.Metal Finishing,2006,104(4):50-56.
[33]http://www.nichia.com/cn/
[34]http://www.phoseon.com
[35]Mukai T,Yamada M,Nakamura S.InGaN-based UV/blue/green/amber LEDs.SPIE,1999.
[36]金尚忠,王东辉等.发光二极管光谱参数测试方法的研究.光电子激光,13(8):825-827.
[37]www.uva.cn 深圳润沃机电公司
[38]朱胜武,施文芳.紫外光固化设备与光固化合物的研究.感光科学与光化学,2001,19(4):295-303.
[39]www.fusionuv.com.cn Richard W.Stowe,揭开紫外光固化的神秘面纱
[40]陈凯良,竺树声.恒流源及其应用电路.浙江科学技术出版社,1992.
[41]ATMEL公司AT89S52的技术手册.
[42]张友德等.单片微型机原理、应用和实验.上海:复旦大学出版社,1996.
[43]张红鑫,卢振武,王瑞庭,等.曲面复眼成像系统的研究.光学精密工程,2006,14(3):346-350.
[44]匡丽娟,翟金会,阮玉,等.复眼透镜阵列应用于均匀照明系统的特性研究.光学与光电技术,2005,3(6):29-31.
[45]刘江,刘承宜,杨友源,等.用于动物细胞和组织培养的新型LED生物光源系列.光子学报,2004,33(2):151-154.
[46]方志良,刘福来,王湘辉,等.高亮度LED铁路信号机光学系统研究.光电子激光,2005,16(12):1433-1436.
[47]何修军,杨华军,邱琪.阵列半导体激光器光束准直设计.激光技术,2004,28(6):528-530.
[48]王璘,施浣芳,王忠厚,等.半导体激光器光束准直系统设计.西安工业学院学报,2004,24(2):141-143.
[49]李士贤,李林.光学设计手册.北京:北京理工大学出版社,1996.
[2]金养智.持续快速发展的中国光固化产业.精细与专用化学品,2004,12(20):3-6.
[3]王建国,滕人瑞.辐射固化——面向21世纪的绿色工业的新技术.原子核物理评论,2000,17(4):243-247.
[4]陈用烈,曾兆华,杨建文等.辐射固化材料及其应用.北京:化学工业出版社,2003.
[5]洪啸吟,金有铠,金养智.中国辐射固化技术发展.热固性树脂,2002,17(1):31-34.
[6]邹应全,张雅静.电子束(EB)固化技术应用大有前途.2005年中国科协学术年会论文集:90-92.
[7]朱胜武,施文芳.紫外光固化设备与光固化合物的研究.感光科学与光化学,2001,19(4):295-301.
[8]吕延晓.全球辐射固化市场动向.精细与专用化学品,2002,(23):7-9.
[9]www.ftachina.org 中国印刷技术协会,紫外线固化技术应用在柔性版印刷上
[10]Bob Goss.Bonding Glass and Other Substrates with UV Curing Adhesives.International Journal of Adhesion and Adhesives,2002,12(5):405-408.
[11]G.V.Shiryaeva,et al.Application of UV/EB cured coating to different substrates.Radiation physics and chemistry,1995(46):995-998.
[12]陈明,洪啸吟.紫外光固化涂料的进展.涂料工业,1999(12):30-36.
[13]王娟娟,马晓燕,晁小练.辐射固化技术研究进展.材料保护,2005,38(1):44-47.
[14]Synder D L.Electroplating nickel/chromium for automotive industry.Metal Finishing,1997(8):29-33
[15]洪啸吟.辐射固化涂料及进展.现代涂料及涂装创刊10周年特刊:8-12.
[16]张钟宪,周荫庄,郑建华等.“绿色”涂料——紫外固化涂料.首都师范大学学报(自然科学版),26(1):57-60.
[17]张强宇,肖新颜.国内紫外光固化涂料的发展及应用.合成材料老化及应用,2004,33(2):26-29.
[18]吕延晓.UV涂料与辐射固化.中国化工报,2005-4-19,006版.
[19]胡学梅,陈红梅,秦长喜等.UV固化涂料在石材上的应用.信息记录材料,2006,7(2):20-22.
[20]纪振鹏.UV油墨的性能及其应用.今日印刷,2006(4).
[21]金养智.紫外线固化技术在数字成像材料中的应用.影像技术,2006(1):8-11.
[22]Miller HC.UV/EB-Cure urethane acrylate and epoxy acrylate coating.Modern Paint and Coatings,1993(12):40.
[23]吕希光,马家举,江棂.辐射固化胶粘剂的应用与研究.中国胶粘剂,2004,13(5):55-59.
[24]杨冬梅,金燕.UV固化胶粘剂在液晶组装中的应用.粘接,2003,24(5):49-50.
[25]张丽华,陈军.紫外光固化胶粘剂的制备及性能研究.华北工学院学报,2003,24(2):131-134.
[26]景惧斌.紫外光固化粘合剂.信息记录材料,2004,5(4):31-36.
[27]黄广新.无处不在的辐射固化技术.信息记录材料,2001,2(2):47-49.
[28]洪啸吟.光固化汽车涂料.现代涂料与涂装,2004(1):32-36.
[29]www.ist-uv.de IST METZ GmbH Nürtingen,Oliver Starzmann,UV Curing Technology
[30]John Maitland.Microwave powered UV curing systems.Wire Industry,2003,70(831):168.
[31]王德海,江棂.紫外光固化材料——理论与应用.北京:科学出版社,2001.
[32]R.W.Stowe.Key Factors in the UV Curing Process-The Relationship of Exposure Conditions and Measurement in UV Process Design and Process Control-Part II:Lamp Systems.Metal Finishing,2006,104(4):50-56.
[33]http://www.nichia.com/cn/
[34]http://www.phoseon.com
[35]Mukai T,Yamada M,Nakamura S.InGaN-based UV/blue/green/amber LEDs.SPIE,1999.
[36]金尚忠,王东辉等.发光二极管光谱参数测试方法的研究.光电子激光,13(8):825-827.
[37]www.uva.cn 深圳润沃机电公司
[38]朱胜武,施文芳.紫外光固化设备与光固化合物的研究.感光科学与光化学,2001,19(4):295-303.
[39]www.fusionuv.com.cn Richard W.Stowe,揭开紫外光固化的神秘面纱
[40]陈凯良,竺树声.恒流源及其应用电路.浙江科学技术出版社,1992.
[41]ATMEL公司AT89S52的技术手册.
[42]张友德等.单片微型机原理、应用和实验.上海:复旦大学出版社,1996.
[43]张红鑫,卢振武,王瑞庭,等.曲面复眼成像系统的研究.光学精密工程,2006,14(3):346-350.
[44]匡丽娟,翟金会,阮玉,等.复眼透镜阵列应用于均匀照明系统的特性研究.光学与光电技术,2005,3(6):29-31.
[45]刘江,刘承宜,杨友源,等.用于动物细胞和组织培养的新型LED生物光源系列.光子学报,2004,33(2):151-154.
[46]方志良,刘福来,王湘辉,等.高亮度LED铁路信号机光学系统研究.光电子激光,2005,16(12):1433-1436.
[47]何修军,杨华军,邱琪.阵列半导体激光器光束准直设计.激光技术,2004,28(6):528-530.
[48]王璘,施浣芳,王忠厚,等.半导体激光器光束准直系统设计.西安工业学院学报,2004,24(2):141-143.
[49]李士贤,李林.光学设计手册.北京:北京理工大学出版社,1996.