Curing system and method of curing
A curing device for curing an ink, varnish, adhesive, and/or adhesive with a lamination film on a web includes a curing housing and a control system. The curing housing includes a light or electron source and an outlet for light or electrons emitted by the light or electron source. The control system is configured to calculate a dosage of light or energy applied to the ink, varnish, adhesive, and/or adhesive with a lamination film. The control system is also configured to adjust or maintain the dosage of light or energy applied to the ink, varnish, adhesive, and/or adhesive with a lamination film based on the calculated dosage of light or energy.
1 . A curing device for curing an ink, varnish, adhesive, and/or adhesive with a lamination film on a web, the curing device comprising:
a curing housing comprising:
a light source that is configured to emit light;
an outlet for light emitted by the light source; and
a filter configured to reflect or transmit light that has wavelength(s) that fall within a predetermined wavelength range toward the outlet;
means for calculating a dosage of light applied to an ink, varnish, adhesive, and/or adhesive with a lamination film on a web via the outlet; and
means for adjusting or maintaining the dosage of light applied to the ink, varnish, adhesive, and/or adhesive with a lamination film on the web based on the calculated dosage of light.
2 . The curing device according to claim 1 , further comprising:
means for determining a speed of the web passing the outlet; and
means for determining an intensity of the light passing through the outlet.
3 . The curing device according to claim 2 , wherein the means for calculating a dosage of light applied to the web is configured to calculate the dosage of light based on the speed of the web and the intensity of the light.
4 . The curing device according to claim 2 , wherein the means for adjusting the dosage of light is configured to adjust the dosage of light by adjusting the intensity of the light and/or the speed of the web.
5 . The curing device according to claim 2 , wherein the means for determining an intensity of the light passing through the outlet comprises at least one radiometer.
6 . The curing device according to claim 1 , further comprising:
at least one temperature sensor configured to measure a temperature of the web; and
control means,
wherein, if the temperature of the web exceeds a predetermined value, the control means is configured to do at least one of the following: (i) activate an alarm; (ii) increase the speed of the web; (iii) decrease the intensity of the light emitted by the housing; and (iv) prevent the light from exiting the housing.
7 . The curing device according to claim 1 , wherein the curing housing further comprises a reflective surface positioned behind the light source, and wherein the reflective surface is configured to reflect light so that the light does not travel back to the light source.
8 . The curing device according to claim 1 , wherein the light source is selected from the group consisting of an arc lamp, an Excimer lamp, and a laser.
9 . The curing device according to claim 1 , wherein the light source is an arc lamp, and wherein a length of the arc lamp is greater than a width of the web.
10 . The curing device according to claim 9 , further comprising:
means for determining a speed of the web passing the outlet; and
means for determining an intensity of the light passing through the outlet.
11 . The curing device according to claim 10 , wherein the means for determining the intensity of the light passing through the outlet comprises at least one radiometer.
12 . The curing device according to claim 10 , wherein the means for determining the speed of a web passing the outlet comprises at least one speedometer.
13 . The curing device according to claim 11 , wherein at least one of the radiometers is aligned with the outlet at a position in which the web is not configured to pass between the radiometer and the arc lamp.
14 . The curing device according to claim 1 , further comprising a temperature sensor configured to monitor a temperature of the web passing the outlet.
15 . The curing device according to claim 1 , wherein the filter is configured to enable UV light to pass therethrough.
16 . The curing device according to claim 1 , further comprising:
an alarm that is configured to alert a technician if the calculated dosage of light differs from a predetermined dosage or is outside a predetermined dosage range.
17 . The curing device according to claim 16 , wherein the predetermined dosage and predetermined dosage range are based on the type and thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.
18 . The curing device according to claim 1 , further comprising:
a heat sink,
wherein the web is positioned between the curing housing outlet and the heat sink.
19 . A curing device for curing an ink, varnish, adhesive, and/or adhesive with a lamination film on a web, the curing device comprising:
a curing housing comprising:
a light source that is configured to emit light;
an outlet for light emitted by the light source; and
a filter configured to reflect or transmit light that has wavelength(s) that fall within a predetermined wavelength range toward the outlet; and
a control system configured to:
calculate a dosage of light applied to an ink, varnish, adhesive, and/or adhesive with a lamination film on a web; and
adjust or maintain the dosage of light applied to the ink, varnish, adhesive, and/or adhesive with a lamination film on the web based on the calculated dosage of light.
20 . The curing device according to claim 19 , wherein the control system is further configured to:
determine a speed of the web passing the outlet; and
determine an intensity of the light passing through the outlet.
21 . The curing device according to claim 20 , wherein the control system is configured to calculate the dosage of light based on the speed of the web and the intensity of the light.
22 . The curing device according to claim 20 , wherein the control system is configured to adjust the dosage of light by adjusting the intensity of the light and/or the speed of the web.
23 . The curing device according to claim 19 , wherein control system comprises at least one radiometer and at least one temperature sensor.
24 . The curing device according to claim 19 , wherein the curing housing further comprises a reflective surface positioned behind the light source, and wherein the reflective surface is configured to reflect light so that the light does not travel back to the light source.
25 . The curing device according to claim 19 , wherein the light source is a selected from the group consisting of an arc lamp, an Excimer lamp, and a laser.
26 . The curing device according to claim 19 , wherein the light source is an arc lamp, and wherein a length of the arc lamp is greater than a width of the web.
27 . The curing device according to claim 26 , wherein the control system is further configured to:
determine a speed of the web passing the outlet; and
determine an intensity of the light passing through the outlet.
28 . The curing device according to claim 27 , wherein the control system comprises at least one radiometer that is configured to measure the intensity of the light.
29 . The curing device according to claim 27 , wherein the control system comprises at least one speedometer that is configured to measure the speed of the web passing the outlet.
30 . The curing device according to claim 28 , wherein at least one of the radiometers is aligned with the outlet at a position in which the web is not configured to pass between the radiometer and the arc lamp.
31 . The curing device according to claim 19 , further comprising:
at least one temperature sensor configured to measure a temperature of the web,
wherein, if the temperature of the web exceeds a predetermined value, the control system is configured do at least one of the following: (i) activate an alarm; (ii) increase the speed of the web; (iii) decrease the intensity of the light emitted by the housing; and (iv) prevent the light from exiting the housing.
32 . The curing device according to claim 19 , wherein the filter is configured to let UV light pass therethrough.
33 . The curing device according to claim 19 , further comprising:
an alarm that is configured to alert a technician if the calculated dosage of light differs from a predetermined dosage or is outside a predetermined dosage range.
34 . The curing device according to claim 33 , wherein the predetermined dosage and predetermined dosage range are based on the type and thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.
35 . The curing device according to claim 19 , further comprising:
a heat sink,
wherein the web is positioned between the curing housing outlet and the heat sink.
36 . A method of curing an ink, varnish, adhesive, and/or adhesive with a lamination film on a web, the method comprising the steps of:
(A) emitting, using a curing housing, light that has wavelength(s) that fall within a predetermined wavelength range;
(B) moving a web past the curing housing;
(C) irradiating an ink, varnish, adhesive, and/or adhesive with a lamination film on the web with the light emitted by the curing housing;
(D) calculating a dosage of the light irradiated onto the ink, varnish, adhesive, and/or adhesive with a lamination film on the web;
(E) comparing the calculated dosage of light to a predetermined dosage or predetermined dosage range; and
(F) performing one of the following steps (i) and (ii):
(i) if the calculated dosage of light is compared in step (E) to a predetermined dosage, performing one of the following steps (a) and (b):
(a) adjusting an intensity of the light and/or a speed of the web if the calculated dosage of light differs from the predetermined dosage; or
(b) maintaining the speed of the web and the intensity of the light, if the calculated dosage of light is substantially the same as the predetermined dosage; or
(ii) if the calculated dosage of light is compared in step (E) to a predetermined dosage range, one of the following steps (c) and (d):
(c) adjusting the intensity of the light and/or the speed of the web if the calculated dosage of light is outside the predetermined dosage range; or
(d) maintaining the speed of the web and the intensity of the light, if the calculated dosage of light is within the predetermined dosage range.
37 . The method according to claim 36 , wherein the step of (F)(i)(a) adjusting the intensity of the light and/or the speed of the web if the calculated dosage of light differs from the predetermined dosage comprises one of the following steps:
(I) decreasing the speed of the web and/or increasing the intensity of the light, if the calculated dosage of light is below the predetermined dosage; or
(II) increasing the speed of the web and/or decreasing the intensity of the light, if the calculated dosage of light is above the predetermined dosage.
38 . The method according to claim 36 , wherein the step of (F)(ii)(c) adjusting the intensity of the light and/or the speed of the web if the calculated dosage of light is outside the predetermined dosage range comprises one of the following steps:
(I) decreasing the speed of the web and/or increasing the intensity of the light, if the calculated dosage of light is below a lower limit of the predetermined dosage range; or
(II) increasing the speed of the web and/or decreasing the intensity of the light, if the calculated dosage of light is above an upper limit of the predetermined dosage range.
39 . The method according to claim 36 , further comprising the step of:
(G) activating an alarm if the calculated dosage of light differs from the predetermined dosage or is outside the predetermined dosage range.
40 . The method according to claim 36 , further comprising the step of:
(G) determining a thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.
41 . The method according to claim 40 , wherein the predetermined dosage and predetermined dosage range are based on the type and thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.
42 . The method according to claim 36 , further comprising the step of:
(G) displaying the light dosage applied to the web.
43 . The method according to claim 36 , further comprising the steps of:
(G) monitoring a temperature of the web; and
(H) performing a control protocol if the temperature of the web exceeds a predetermined value.
44 . The method according to claim 43 , wherein the control protocol comprises at least one of: (i) activating an alarm; (ii) increasing the speed of the web; (iii) decreasing the intensity of the light emitted by the housing; and (iv) preventing the light from exiting the housing.
45 . The method according to claim 36 , wherein the step of (D) calculating a dosage of the light comprises the steps of:
(i) measuring the speed of the web passing the curing housing;
(ii) measuring the intensity of the light emitted by the curing housing;
(iii) calculating a duration during which the web is exposed to the light based on the measured speed of the web; and
(iv) multiplying the calculated duration and the measured intensity of the light.
46 . The method according to claim 45 , wherein the step of (D)(ii) measuring the intensity of the light emitted by the curing housing is performed using a test sensor before the step of (B) moving a web past the curing housing.
47 . A curing device for curing an ink, varnish, adhesive, and/or adhesive with a lamination film on a web, the curing device comprising:
an electron beam curing housing comprising:
an electron source that is configured to emit electrons; and
an outlet for electrons emitted by the electron source; and
a control system configured to:
calculate a dosage of energy applied to an ink, varnish, adhesive, and/or adhesive with a lamination film on a web; and
adjust or maintain the dosage of energy applied to the ink, varnish, adhesive, and/or adhesive with a lamination film on the web based on the calculated dosage of energy.
48 . The curing device according to claim 47 , wherein the control system is configured to adjust the dosage of energy by adjusting an amount of energy absorbed per unit of mass of the ink, varnish, adhesive, and/or adhesive with a lamination film on the web.
49 . The curing device according to claim 47 , wherein the control system is further configured to determine an intensity of the energy passing through the outlet and a speed of the web.
50 . The curing device according to claim 49 , wherein the control system is further configured to adjust the dosage of energy by adjusting the intensity of the energy and/or the speed of the web.
51 . The curing device according to claim 47 , wherein the control system comprises at least one electron sensor and at least one temperature sensor.
52 . The curing device according to claim 51 , wherein at least one of the electron sensors is aligned with the outlet at a position in which the web is not configured to pass between the electron sensor and the electron beam curing housing.
53 . The curing device according to claim 47 , wherein the curing housing further comprises a repeller plate positioned behind the electron source.
54 . The curing device according to claim 47 , wherein the control system comprises at least one speedometer that is configured to measure the speed of the web passing the outlet.
55 . The curing device according to claim 47 , further comprising:
at least one temperature sensor configured to measure a temperature of the web,
wherein, if the temperature of the web exceeds a predetermined value, the control system is configured do at least one of the following: (i) activate an alarm; (ii) increase the speed of the web; (iii) decrease the intensity of the electrons emitted by the housing; and (iv) prevent the electrons from exiting the housing.
56 . The curing device according to claim 47 , further comprising:
an alarm that is configured to alert a technician if the calculated dosage of energy differs from a predetermined dosage or is outside a predetermined dosage range.
57 . The curing device according to claim 56 , wherein the predetermined dosage and predetermined dosage range are based on the type and thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.
58 . The curing device according to claim 47 , further comprising:
a shield aligned with the curing housing outlet,
wherein the web is positioned between the curing housing outlet and the shield.
59 . A method of curing an ink, varnish, adhesive, and/or adhesive with a lamination film on a web, the method comprising the steps of:
(A) emitting, using a curing housing, electrons;
(B) moving a web past the curing housing;
(C) irradiating an ink, varnish, adhesive, and/or adhesive with a lamination film on the web with the electrons emitted by the curing housing;
(D) calculating a dosage of energy irradiated onto the ink, varnish, adhesive, and/or adhesive with a lamination film on the web;
(E) comparing the calculated dosage of energy to a predetermined dosage or predetermined dosage range; and
(F) performing one of the following steps (i) and (ii):
(i) if the calculated dosage of energy is compared in step (E) to a predetermined dosage, performing one of the following steps (a) and (b):
(a) adjusting an intensity of the energy and/or a speed of the web if the calculated dosage of energy differs from the predetermined dosage; or
(b) maintaining the speed of the web and the intensity of the energy, if the calculated dosage of energy is substantially the same as the predetermined dosage; or
(ii) if the calculated dosage of energy is compared in step (E) to a predetermined dosage range, performing one of the following steps (c) and (d):
(c) adjusting an intensity of the energy and/or a speed of the web if the calculated dosage of energy is outside the predetermined dosage range; or
(d) maintaining the speed of the web and the intensity of the energy, if the calculated dosage of energy is within the predetermined dosage range.
60 . The method according to claim 59 , wherein the step of (F)(i)(a) adjusting the intensity of the energy and/or the speed of the web if the calculated dosage of energy differs from the predetermined dosage comprises one of the following steps:
(I) decreasing the speed of the web and/or increasing the intensity of the energy, if the calculated dosage of energy is below the predetermined dosage; or
(II) increasing the speed of the web and/or decreasing the intensity of the energy, if the calculated dosage of energy is above the predetermined dosage.
61 . The method according to claim 59 , wherein the step of (F)(ii)(c) adjusting the intensity of the energy and/or the speed of the web if the calculated dosage of energy is outside the predetermined dosage range comprises one of the following steps:
(I) decreasing the speed of the web and/or increasing the intensity of the energy, if the calculated dosage of energy is below a lower limit of the predetermined dosage range; or
(II) increasing the speed of the web and/or decreasing the intensity of the energy, if the calculated dosage of energy is above an upper limit of the predetermined dosage range.
62 . The method according to claim 59 , wherein the step of (D) calculating a dosage of the energy comprises determining an amount of energy absorbed per unit of mass of the ink, varnish, adhesive, and/or adhesive with a lamination film on the web.
63 . The method according to claim 59 , further comprising the step of:
(G) activating an alarm if the calculated dosage of energy differs from the predetermined dosage or is outside the predetermined dosage range.
64 . The method according to claim 59 , further comprising the step of:
(G) determining a thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.
65 . The method according to claim 64 , wherein the predetermined dosage and predetermined range are based on the type and thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.
66 . The method according to claim 59 , further comprising the step of:
(G) displaying the energy dosage applied to the web.
67 . The method according to claim 59 , further comprising the steps of:
(G) monitoring a temperature of the web; and
(H) performing a control protocol if the temperature of the web exceeds a predetermined value.
68 . The method according to claim 67 , wherein the control protocol comprises at least one of: (i) activating an alarm; (ii) increasing the speed of the web; (iii) decreasing the number of electrons emitted by the housing; and (iv) preventing the electrons from exiting the housing.
69 . The method according to claim 59 , wherein the step of (D) calculating a dosage of energy irradiated onto the ink, varnish, adhesive, and/or adhesive with a lamination film on the web comprises the steps of:
(i) measuring the speed of the web passing the curing housing;
(ii) measuring the intensity of the electrons emitted by the curing housing; and
(iii) calculating, based on the speed of the web, a duration during which the ink, varnish, adhesive, and/or adhesive with a lamination film on the web is exposed to the electrons.
70 . The method according to claim 69 , wherein the step of (D) calculating a dosage of energy irradiated onto the ink, varnish, adhesive, and/or adhesive with a lamination film on the web further comprises the steps of:
(iv) multiplying the intensity of the electrons by the duration to obtain a calculated energy per area;
(v) multiplying the calculated energy per area by an area of the ink, varnish, adhesive, and/or adhesive with a lamination film on the web that is exposed to the electrons to obtain a calculated total energy;
(vi) multiplying the volume of the ink, varnish, adhesive, and/or adhesive with a lamination film exposed to the electrons by the density of the ink, varnish, adhesive, and/or adhesive with a lamination film exposed to the electrons to obtain a calculated mass; and
(vii) dividing the calculated total energy by the calculated mass.
71 . The method according to claim 69 , wherein the step of (D)(ii) measuring the intensity of the electrons emitted by the curing housing is performed using a test sensor before the step of (B) moving a web past the curing housing.
72 . A control system for a curing device, the system comprising an alarm that is configured to alert a technician if a calculated dosage of:
(a) light emitted by a curing housing differs from a predetermined light dosage or is outside a predetermined light dosage range; or
(b) energy emitted by an electron beam curing housing differs from a predetermined energy dosage or is outside a predetermined energy dosage range.
73 . The control system according to claim 72 , wherein the predetermined light dosage and predetermined light dosage range are based on a type and thickness of an ink, varnish, adhesive, and/or adhesive with a lamination film applied to a web.
74 . The control system according to claim 72 , wherein the predetermined energy dosage and predetermined energy dosage range are based on a type and thickness of an ink, varnish, adhesive, and/or adhesive with a lamination film applied to a web.
75 . The control system according to claim 72 , wherein the alarm is further configured to alert a technician if the calculated dosage of:
(c) light emitted by the curing housing is nearing a limit of the predetermined light dosage range; or
(d) energy emitted by the electron beam curing housing is nearing a limit of the predetermined energy dosage range.
76 . A control system for a curing device, the control system comprising:
means for calculating a dosage of light applied to an ink, varnish, adhesive, and/or adhesive with a lamination film on a web; and
means for adjusting or maintaining the dosage of light applied to the ink, varnish, adhesive, and/or adhesive with a lamination film on the web based on the calculated dosage of light.
77 . The control system according to claim 76 , further comprising:
means for determining a speed of the web; and
means for determining an intensity of the light applied to the web.
78 . The control system according to claim 77 , wherein the means for calculating a dosage of light applied to the web is configured to calculate the dosage of light based on the speed of the web and the intensity of the light.
79 . The control system according to claim 77 , wherein the means for adjusting the dosage of light is configured to adjust the dosage of light by adjusting the intensity of the light and/or the speed of the web.
80 . The control system according to claim 77 , wherein the means for determining an intensity of the light applied to the web comprises at least one radiometer.
81 . The control system according to claim 76 , further comprising:
at least one temperature sensor configured to measure a temperature of the web.
82 . The control system according to claim 81 , further comprising:
control means,
wherein, if the temperature of the web exceeds a predetermined value, the control means is configured to do at least one of the following: (i) activate an alarm; (ii) increase the speed of the web; (iii) decrease the intensity of the light applied to the web; and (iv) prevent the light from being applied to the web.
83 . The control system according to claim 76 , further comprising:
an alarm that is configured to alert a technician if the calculated dosage of light differs from a predetermined dosage or is outside a predetermined dosage range.
84 . The control system according to claim 83 , wherein the predetermined dosage and predetermined dosage range are based on the type and thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.
85 . A control system for a curing device, the control system comprising:
means for calculating a dosage of energy applied to an ink, varnish, adhesive, and/or adhesive with a lamination film on a web; and
means for adjusting or maintaining the dosage of energy applied to the ink, varnish, adhesive, and/or adhesive with a lamination film on the web based on the calculated dosage of energy.
86 . The control system according to claim 85 , further comprising:
means for determining a speed of the web; and
means for determining an intensity of the energy applied to the web.
87 . The control system according to claim 86 , wherein the means for calculating a dosage of energy applied to the web is configured to calculate the dosage of energy based on the speed of the web and the intensity of the energy.
88 . The control system according to claim 86 , wherein the means for adjusting the dosage of energy is configured to adjust the dosage of energy by adjusting the intensity of the energy and/or the speed of the web.
89 . The control system according to claim 86 , wherein the means for determining an intensity of the energy applied to the web comprises at least one electron sensor.
90 . The control system according to claim 85 , further comprising:
at least one temperature sensor configured to measure a temperature of the web.
91 . The control system according to claim 90 , further comprising:
control means,
wherein, if the temperature of the web exceeds a predetermined value, the control means is configured to do at least one of the following: (i) activate an alarm; (ii) increase the speed of the web; (iii) decrease the intensity of the energy applied to the web; and (iv) prevent the energy from being applied to the web.
92 . The control system according to claim 85 , further comprising:
an alarm that is configured to alert a technician if the calculated dosage of energy differs from a predetermined dosage or is outside a predetermined dosage range.
93 . The control system according to claim 92 , wherein the predetermined dosage and predetermined dosage range are based on the type and thickness of the ink, varnish, adhesive, and/or adhesive with a lamination film applied to the web.