DESCRIPTION

CURING SYSTEM

Embodiments relate to a curing system, for example to a curing system for curing a component coated with a light curable coating.

The process of curing refers to the toughening or hardening of a polymer material by cross-linking of polymer chains and this may be brought about by chemical additives, light for example ultraviolet radiation (UV) , electron beam (EB) or heat.

Curing systems typically include a light source as a source of ultraviolet radiation for curing of components. The light source provides a range of wavelengths which makes them suitable for a variety of inks and coatings which may respond to the different wavelengths.

Further, the curing systems typically require a sizeable area to accommodate all the components to be cured so as to allow for sufficient exposure to the UV radiation.

Also, in order to achieve rapid curing of components, the light source is typically driven at a relatively high power to generate a sufficient intensity of UV radiation. This may- give rise to a considerable amount of energy which may result in overheating of the curing systems.

In various embodiments, a curing system is provided, which is able to prevent deformation of components caused by a high temperature and an uneven exposure to UV radiation.

An embodiment relates to a curing system for curing a component coated with a light curable coating. The curing system may include a housing having an internal reflective surface; a fluid housed within the housing; and a light source for producing light; wherein the component is positioned within the fluid and the internal reflective surface is configured to reflect the light onto the component to cure the light curable coating.

In an embodiment, a component may be configured to a desired shape before curing in the curing system. The curing process may provide for a change in shape of the component, for example into a desired shape, after being cured by the curing system. By way of example, the shape of a hearing tube or sound pipe may be changed by curing using the curing system

In an embodiment, the component itself may be light sensitive instead of being coated with a light curable coating.

In an embodiment, the component may be positioned between the internal reflective surface and the light source. As an example, the component may be surrounded by the fluid housed within the housing.

In an embodiment, the light source may be positioned within or above the housing. The light source may also be positioned away from the housing. Further, the light source may be positioned within or away from the fluid. As an example, for the light source positioned within the housing, the light source may be positioned at a centre, a top, a bottom and a side of the housing.

In an embodiment, the housing (or may also be referred to as a curing box) may include a material selected from a group consisting of steel and plastic. The housing may also include a material which may allow light to penetrate through. The housing may include a thickness in the range from about 1 mm to about 50 mm.

In an embodiment, the fluid may be selected from a group consisting of water, oil and emulsion. The fluid may also include any fluid compatible with the component disposed within the housing. The fluid may also include any fluid that has a suitable density to be adopted for curing in the housing. As an example, the density of the fluid may allow rotation of the fluid within the housing, thereby enabling the components to be circulated within the housing in order to obtain maximum light exposure. Further, the fluid may also include a fluid which may contain reflective particles so as to enable light to be reflected onto the components.

In an embodiment, the light source may be selected from the group consisting of an UV light source, an infrared (IR) light source, a blue light source and a red light source. For example, the light source may include a low, medium, high pressure mercury arc bulb (which can be doped with various metals to achieve specific wavelengths), a fluorescent bulb, a light-emitting diode (LED) , a non-mercury pulsed arc lamp or other appropriate lamp, bulb, or light source. Some examples of UV light source include an arc lamp, an excimer lamp, a laser, and an electron beam generator.

In an embodiment, the light source may be configured to produce light of a predetermined wavelength, wherein the predetermined wavelength is selected depending on a characteristic of the light curable coating. As an example, light may include different spectra, such as UV light, IR light, blue light and red light.

In an embodiment, the characteristic of the light curable coating may include color or dimension of the light curable coating. The color and/or the thickness of the light curable coating may also determine the intensity of light and dwell time required to obtain a full cure.

In an embodiment, the component may include a regular shape or an irregular shape. The regular shape may include a shape selected from a group consisting of square, circle, diamond and rectangle. The irregular shape may include a shape with irregular corners and edges which may make it difficult for the light to reach. The component may include a single complete portion and an irregular shaped portion with inner and outer surfaces to be cured.

In an embodiment, the light curable coating may be selected from the group consisting of a light curable ink, an adhesive .

In an embodiment, the internal reflective surface may include a mirror or any suitable reflective coating which may be disposed on a surface of the housing. The internal reflective surface may include tiny glass particles that may reflect light in different directions.

In an embodiment, the mirror may be selected from a group consisting of a plane mirror, a convex mirror, a concave mirror, a glass mirror and a metal mirror.

In an embodiment, the curing system may further include a housing cover positioned over an opening on the housing. The housing cover may be made of a similar material as the housing. The edges of the housing may be straight, dome- shaped, curve or any other suitable shapes which may enable optimum reflection of the light. The housing cover may also be straight, dome-shaped, curve or any other suitable shapes which may enable optimum reflection of the light.

In an embodiment, the dimensions of the housing may be up to e.g. about 2000 mm (length), 4000 mm (breadth) and 4700 mm (height) . The dimensions of each component may be about 400 mm (length), 300 mm (breadth) and 350 mm (height). Each component may have any suitable dimension corresponding to the dimension of the housing and vice versa, i.e. e.g. dimensions smaller or greater than those outlined above.

In an embodiment, the intensity of light incident onto each component may be inversely proportional to the distance of each component from the light source. In an embodiment, the fluid within the housing allows for even curing of the components on all surfaces. The fluid also helps to prevent the components from being damaged by heat.

In an embodiment, it may be possible to place more than one component or type of component in the curing system without having to arrange each component in a predefined manner. The fluid within the housing may prevent the components from sticking together or coming in direct contact with each other. The fluid may also prevent oxidation of the components .

In an embodiment, the light may help to disinfect, clean and sterilize the component completely. And as there is no need for an enclosed inert environment, there is no need to fill the surrounding environment with an inert gas, such as nitrogen. Further, materials that are not nitrogen-compatible may now be cured.

In an embodiment, the component may be a hearing aid housing (e.g. also a hearing aid audio shoe housing, a hearing aid shell) , a sound pipe, a tooth or any component which adopts light as a medium for curing. A so-called audio shoe may be a small device attached to a hearing aid, for example a Behind- The-Ear (BTE) hearing aid, used to connect a FM receiver or other similar device.

In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the invention are described with reference to the following drawings, in which: Figures IA and IB show respective top view and cross- sectional view of a curing system according to an embodiment; and

Figures 2A and 2B show respective In The Ear and Behind The Ear hearing aids with components cured using the curing system of Figures IA and IB according to an embodiment;

Figures 3A and 3B show a sound pipe in a Behind The Ear hearing aid before and after being cured using the curing system of Figures IA and IB according to an embodiment .

Fig. IA and Fig. IB show respective top view and cross- sectional view of a curing system according to an embodiment.

As can be seen in Fig. IA, the curing system 102 for curing a component 104 may include a housing 106 having an internal reflective surface 108, a fluid 110 housed within the housing 106 and a light source 112 for producing light. The component 104 may include a component coated with a light curable coating or a light-sensitive component. The component 104 may be positioned within the fluid 110 and the internal reflective surface 108 is configured to reflect the light onto the component 104 to cure the light curable coating on the component 104 or the light-sensitive component 104.

The component 104 may be positioned between the internal reflective surface 108 and the light source 112. The light source 112 may be positioned within the housing 106, at around the centre of the housing 106.

In an embodiment, the housing 106 may include a material selected from a group consisting of steel and plastic. The fluid 110 may be selected from a group consisting of water, oil and emulsion. In an embodiment, the light source 112 may be selected from the group consisting of an ultraviolet light source, an infrared light source, a blue light source and a red light source. The light source 112 may be configured to produce light of a predetermined wavelength, wherein the predetermined wavelength may be selected depending on a characteristic of the light curable coating. The characteristic of the light curable coating may include color or dimension of the light curable coating.

In an embodiment, the light source 112 may be positioned at any suitable position within the curing system 102. By way of example, Fig. IA shows direction of reflection of the light (as shown by the arrows) but is not so limited.

In an embodiment, the component 104 may include a regular shape or an irregular shape. The regular shape may be selected from a group consisting of square, circle, diamond and rectangle. The irregular shape may be any shape with irregular corners and edges which may make it difficult for the light to reach.

In an embodiment, the light curable coating is selected from the group consisting of a light curable ink, an adhesive.

In an embodiment, the internal reflective surface 108 may- include a mirror. The mirror may be selected from a group consisting of a plane mirror, a convex mirror, a concave mirror, a glass mirror and a metal mirror.

In an embodiment, the reflection or path of light is as seen by the arrows shown in Figures IA and IB.

Fig. IB is a cross-sectional view along line A-A as shown in Figure IA. As further seen in Figure IB, the curing system 102 may include a housing cover 114, positioned over an opening of the housing 106. The housing cover 114 may be made of a similar material as the housing 106. The housing cover 114 may prevent any unwanted material from coming in contact with the fluid 110 or component 104 in the housing 106, thereby affecting the curing process. The housing cover 114 may also be used to enclose the light source 112 so as to prevent the light from escaping from within the curing system 102. Further, the housing cover 114 may also enclose the curing system, thereby providing an all-directional (360 degree) curing surface for maximum curing effect.

The light source 112 may extend along the height (denoted by "H") of the housing 106 or may be positioned at a single spot within the housing 106, the design and position of the light source 112 may be adapted according to user requirements.

Fig.2A and Fig.2B show respective In The Ear (ITE) and Behind The Ear (BTE) hearing aids 116 with components cured using the curing system 102 of Fig. IA and Fig. IB according to an embodiment .

By way of example, Fig.2A shows an ITE hearing aid 116. In general, an ITE hearing aid 116 is a custom style of hearing aid, filling the bowl of a hearing aid user's ear.

In an embodiment, the ITE hearing aid 116 includes a hearing aid housing 118 which may be cured using the curing system 102 of Fig. IA and Fig. IB. In an embodiment, two or more parts of the hearing aid 116 or of the hearing aid housing 118 may also be separately cured before being assembled to form the hearing aid 116.

By way of example, Fig.2B shows a Behind The Ear (BTE) hearing aid 116. The BTE hearing aid 116 may include components such as a hearing aid housing 118 and an ear hook or sound pipe 120. The sound pipe 120 may be a piece of plastic tubing that couples the hearing aid housing 118 to a custom ear mold (not shown) , thereby allowing sound to be transmitted into a hearing user's ear canal. In an embodiment, the hearing aid housing 118 and the sound pipe 120 may be separately cured using the curing system 102 of Fig. IA and Fig. IB. In an embodiment, two or more parts of the hearing aid 116 or of the hearing aid housing 118 may also be separately cured before being assembled to form the hearing aid 116.

It is to be noted, that any other suitable components of the hearing aid 116 may also be cured using the curing system 102 of Fig. IA and Fig. IB. The components of some other types of hearing aids besides the ITE and BTE aids such as in the canal (ITC) aid, completely in the canal (CIC) aid, etc may also be cured using the curing system 102 of Fig. IA and Fig. IB.

Fig.3A and Fig.3B show a sound pipe 120 in a BTE hearing aid 116 before and after being cured using the curing system 102 of Fig. IA and Fig. IB according to an embodiment.

Fig.3A and Fig.3B respective show a hearing aid 116 including a cap 122, a sound pipe 120 and a honey tipper 124. A cap 122 is a flexible ear hook adapted to be fixed to a nozzle of a housing of a BTE hearing aid 116. One end of the honey tipper 124 may be connected to the cap 122 via the sound pipe 120 and the other end may be adapted to be fitted into the ear.

Fig.3A shows a relatively straight sound pipe 120 before curing and Fig.3B shows the sound pipe 120 with a desired shape after being cured using the curing system 102 of Fig. IA and Fig. IB. Fig.3A and Fig.3B shows that shaping or reforming a component may be possible through curing using the curing system of Fig. IA and Fig. IB.

While the invention has been particularly shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. The scope of the invention is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced.