However, a common question often associated with UV LEDs is: do they pose any safety risks? Many misconceptions still exist concerning the safety of the materials and equipment used in UV LED curing. This blog post will serve as a guide to UV LED curing system safety measures explaining the hazards associated with UV light and recommending protective measures for a safe work environment. 

Understanding the Hazards of UV Light  

UV radiation is in the form of electromagnetic radiation, with wavelengths ranging from 100nm to 400nm. Based on the range, UV light can be classified as- 

• UVA- ranging from 315nm to 400nm. 
• UVB- ranging from 280nm to 315nm. 
• UVC- ranging from 100nm to 280nm. 
• UVV- ranging from 395nm to 455nm.  

The optimum wavelength used for UV curing depends on several factors, but UVA is the typical wavelength range used for UV curing. UVC LEDs are a relatively new, rapidly improving technology and are predominately available from 265nm to 285nm. 

Risks associated with exposure to UV light 

A large proportion of UV light output is not visible to the human eye and the UVA spectrum is considered the safest spectra of UV light. Overexposure to UV light can still result in poor skin and eye safety, which has been linked to accelerated skin ageing, carcinoma, melanoma, cataracts, Pterygium (or Surfer’s eye), and eye cancers. It is best to limit exposure to UV LED curing systems, which can be managed with simple precautions. Some of them are listed below- 

• Don’t look directly into the UV LED light when in operation. To prevent overexposure, wear protective eyewear. We will talk more about the protective measures in the next section. 
• Assume all lights are powered and invisible unless you are certain.  
• Do not assume any blue or red lights are dull. 
• Do not place your hands unprotected under the curing lamps. 
• Be aware of what products are being used near to your workstation. 

Implementing Protective Measures  

UV light sources produce moderate to high levels of intensity at close range. This intensity is inversely proportional to the squared distance from the light source. To make UV LED curing a personnel-friendly manufacturing process, it is pertinent to utilize recommended safe handling procedures, industrial hygiene practices, proper worker/operator training operator and safety equipment.  

Threshold Limit Values (TLVs) 

The American Conference of Governmental Industrial Hygienists (ACGIH) recommends values for exposure of the eyes or skin applicable for UV radiation from fluorescent and incandescent sources, in addition to arc, gas and vapor discharges. The recommended TLV for UVA wavelength region (315 to 400 nm) should not exceed 1.0 mW/cm2 for a period greater than 1,000 seconds (approximately 16.7 minutes), and for exposure time less than 1,000 seconds, the total energy should not exceed 1.0 J/cm2. 

To put this in perspective the COBRA Cure FX1, one of our lowest intensity lamps, emits 6.5 W/cm2 at 2mm, 6500 times the safe eye limit.  

Personal Protective Equipment (PPE) 

ProPhotonix recommends that personnel dealing with UV radiation should wear PPE including UV blocking eyewear and completely cover skin which may be exposed to UV light. For eye safety, these UV certified glasses are recommended based on the wavelength being used in your application. 

• LG2 glasses for wavelengths 365, 385, 405 
• LG3 glasses for wavelengths 365, 385, 405 
• LG4 glasses for wavelengths 365 

Face shields can also be used as an added layer for eye protection. Personnel working in close proximity to UV radiation sources must also wear fully buttoned lab coats, disposable nitrile or latex gloves, and closed toe shoes at all times.  

Ventilation & Shielding 

In order to protect personnel working at a UV LED curing facility, the managing team must ensure that the place is completely hazard free. While ventilation is not necessary to protect the worker from UV radiation, it is needed to remove any toxic gases that may be created by the interaction of UV LED system with material being cured and atmospheric contaminants. Additionally, side and back screens should also be used to protect workers in and around the workspace. 

Compliance with Safety Regulations  

UV LED curing system designers should be aware of the standards for light emitting diode (LED) equipment for use in lighting products, related global safety standards, and how recent changes and new market developments impact testing and certification. 

Regulatory bodies overseeing UV LED curing safety 

OSHA 

There is no Occupational Safety and Health Administration (OSHA) standard regarding exposure to ultraviolet light, but the OSHA general duty clause states the employer must provide a workplace free of recognized hazards that may cause death or serious physical harm. 

ANSI 

ANSI/UL 8750 covers LED equipment that is an integral part of a luminaire or other lighting equipment, and which operates in the visible light spectrum of 400–700 nm. The standard also applies to the component parts of LED equipment, including LED drivers, controllers, arrays, modules, and packages. 

IEC 

The IEC (International Electrotechnical Commission) is the world’s leading organization that prepares and publishes International Standards for all electrical, electronic and related technologies. ProPhotonix light sources are classified as Risk Group 3 under IEC 62471 at a distance of 200mm. Risk groups defined in IEC 62471: 

Exempt means there is no photo-biological hazard for the end points in this standard. 

• Risk Group 1 – Low Risk. Does not pose a hazard due to normal behavioral limitations on exposure. 
• Risk Group 2 – Moderate Risk. Does not pose a hazard due to aversion response to very bright light sources or due to thermal discomfort. 
• Risk Group 3 – High Risk. May pose a hazard even for momentary or brief exposure. 

Labelling 

UV LED curing systems must indicate warning labels against the UV range used and the associated risks. 

Maintenance and Inspection of UV LED Curing Systems  

While UV LED curing systems provide significantly longer lifespans and lower maintenance expenses, it is crucial to conduct consistent maintenance and inspection to ensure a thriving UV curing system. These curing systems are frequently operated in less-than-ideal industrial environments, causing them to age and fail prematurely, leading to inefficient curing.  

Regular inspection of UV LED lamps used in your curing solution can help detect any potential attenuation of light. Additionally, the following steps can help prevent inefficient curing and allows UV LED curing systems to function properly- 

• Check for any abnormalities at regular intervals of time, fix immediately if there is any abnormality. 
• Allow lamps to cool properly once the system has been turned off. This step will help extend lamp life substantially. 
• Change air filters to allow maximum cooling of your UV LED curing system. 
• Check LED lamps and reflectors closely for any residue or accumulated dust, use an approved cleaner and a suitable cleaning cloth or soft tissue to remove any residue. 
• Blow out and clean dust on the surface, interior (working area) of the UV curing machine. 
• Clean and check clamping for a firm fit. If your UV LED curing system uses a glass or quartz plate like COBRA Cure FX2, check and replace it for consistent, reliable cure. 
• Maintain a regular inspection routine to avoid possible buckling of UV LED lamps in the system.

It is important to remember that for all maintenance/inspection work described above, the system must be completely disconnected from all services (electrical power, compressed air, vacuum etc.). If end users are unsure about the quality of the UV curing system’s safety equipment, they should use a UV meter/radiometer to measure stray radiant energy at the location of interest. 

Conclusion  

In conclusion, implementing safety measures for UV LED curing systems is not just a legal obligation, but also a moral responsibility that employers owe to their employees. It is imperative to establish comprehensive safety protocols that involve training employees, providing personal protective equipment (PPE), and installing protective barriers where applicable. As a UV LED curing solutions provider, ProPhotonix encourages the initiative to educate personnel on UV LED safety measures and advocate for their implementation in workplaces. 

The post A Guide to UV LED Curing Safety Measures: Ensuring a Safe Work Environment appeared first on Prophotonix.

Choosing the Right LED Wavelength 

Selecting the appropriate wavelength is a pivotal aspect in maximizing the efficiency of UV LED curing systems. While we covered wavelength selection in the previous blog, let’s explore this topic from a different perspective, focusing on how it directly impacts the efficiency of the curing process. 

Enhanced Curing Performance 

The right LED wavelength significantly contributes to faster and more efficient curing. By selecting the optimal wavelength, you can decrease curing time and improve the overall quality of the cure, ultimately maximizing efficiency. 

Customization and Optimization 

UV LED sources offer system designers the advantage of working with specific wavelengths or multiple wavelengths, allowing for greater customization and optimization of the curing system. This flexibility enables system designers to fine-tune the curing process to specific materials and applications, optimizing efficiency. 

Multi-Wavelength Systems 

In certain cases, the use of multi-wavelength systems can provide enhanced flexibility and efficiency. By incorporating various wavelengths, you can effectively address diverse curing needs, streamlining production processes and maximizing overall efficiency. 

Material Compatibility 

Matching the absorption characteristics of the materials with the appropriate wavelength ensures optimal energy transfer, maximizing efficiency and reducing energy waste. 

Proper LED Placement 

LED technology is fundamentally a more compact technology than traditional lamps due to the LED packing densities possible. A variety of LED array methods such as through hole (T-pack), surface mount or chip-on-board can be implemented for different LED packing densities. 

ProPhotonix utilizes Chip-on-Board LED technology in which the bare chip is placed in direct contact with the substrate allowing greater design flexibility, greater intensity and uniformity. For example, LED substrates can be designed on flexible substrates, spherical substrates or as in the COBRA Cure FX series, the LEDs can be placed with an asymmetric distribution so that a higher distribution of LEDs is located near the edges of a lamp to mitigate shadowing effects which also results in higher intensity. 

Optimal Cooling 

UV LED lamps typically require fan or water-cooled systems to guarantee reliable continuous operation over the entire operating temperature range although some low power lamps are available that rely solely on convection cooling. Fan– cooled systems do not require any ancillary equipment, but higher intensity fan-cooled systems may become bulky due to the requirement for bigger and/or more fans to regulate the temperature.  

In environments where there are airborne particulates, filters can be attached to the lamp’s openings to reduce the access of these particles into the inner workings of the UV LED lamp. ProPhotonix offers a range of direct air-cooled UV LED systems with the COBRA Cure FX series. 

Effective Optics 

Optical design of UV LED curing systems is important to ensure that your system works efficiently and that all of the output generated by the UV LED system reaches the target material and cures the correct surface area. If the optical design of the UV lamp is not optimized, under-curing or over-curing can occur. For example, in print applications, if the ink is over-cured, the process results could be banding and other issues. Conversely, inefficient design or poorly fitted optics can result in a significantly reduced light output onto the target area resulting in under-curing of the target material. 

Optical requirements can differ from one application to another. For this reason, ProPhotonix has an in-house optical engineering team that can develop an optimized illumination system to satisfy your requirements. 

Controlled Irradiance 

An inherent challenge with LED curing systems is to maintain the high irradiance over working distances due to the divergence of light from the LED source. Measurement of irradiance is essential in order to optimize cure conditions and maintain consistency in cure results. By implementing techniques to overcome light divergence, optimizing optical design, and utilizing dynamic power control, engineers and system designers can achieve consistent and controlled irradiance levels.  

Regular Maintenance 

UV LEDs do not generate excess heat and as such are a “cool” cure technology ideal for curing materials on heat-sensitive substrates such as wood or plastics that might be damaged by the high temperatures generated from traditional mercury lamps. Maintenance downtimes and the costs involved will be lower because of the extended life of LEDs providing less production downtime versus the changeout required by mercury lamps.  

Conclusion 

Operating efficiency of UV LED curing systems is improved as a result of the unique control capability of light uniformity, speed of flash and precise spectral output among other factors. Following several years of research and customer trials, ProPhotonix launched the COBRA Cure FX series. The product range, designed specifically for UV curing of inks, coatings, and adhesives, offers the flexibility to configure a UV LED curing system to specific application needs.  

It is important to remember that the inherent advantages of UV LED curing systems over traditional UV lamps are not only about improved performance and higher efficiency but also about environmental friendliness and safety. Our next blog post will dive deeper into the safety measures for UV LED curing systems. With 15 years of experience in UV LEDs, ProPhotonix’ UV LED Curing systems can help maximize system performance. We have also worked with customers to design and produce custom UV LED solutions for more than two decades. 

The post Maximizing the Efficiency of UV LED Curing Systems: Tips & Techniques appeared first on Prophotonix.

Flexible form factors, multi-wavelength capability, greater control, stability, shorter cure time, greater energy efficiency, and reduced running costs are just a few factors which make UV LED curing systems better. If you have been considering moving from mercury lamps due to time-cost-performance issues, this blog post can guide you in selecting the right UV LED curing system for your business. 

Determine Your UV LED Curing Requirements 

UV curing is a photopolymerization process in which UV energy is used to change a liquid to a solid, by triggering photoinitiators in the liquid. UV LED lamps emit a narrower frequency range than traditional broad-spectrum mercury UV lamps. LED products are available in a range of wavelengths and customizable to specific application requirements making it easier to manage the narrow wavelength and match it with the photoinitiators’ trigger wavelength. 

To optimize a UV LED curing system for various applications, it is imperative to consider the following factors- 

Wavelength Selection

Choosing the right wavelength is vital for a high-quality cure in minimal time. For example, a 365nm light may be the optimum wavelength to cure based on the target materials absorption profile, 395nm may still produce a better curing result due to efficiency and “cost per watt” differences between the LEDs. 

Light Output Profile 

Defining the output profile for your UV LED curing system is crucial. Narrower light outputs may be necessary in certain applications to avoid unwanted curing, such as curing of material on print heads. ProPhotonix offers a range of light output configurations including low angle (collimated), medium angle and wide angle with the COBRA Cure FX series. 

Working Distance 

The working distance requirements of an application impact the LED lamp’s optical design. Although these UV LED curing systems typically work over a short working distance, certain applications may require a different optical system to provide a longer working distance and/or a wider depth of focus when curing objects of varying sizes. 

Intensity & Dose 

UV curable media require both a minimum intensity and a minimum dose for an effective cure. If the intensity is too high, it can damage the ink or resin. A balance needs to be struck between the required intensity and dose level.  

If your application requires specific optical considerations, ProPhotonix can work with you to design application specific UV LED curing systems. 

Evaluate UV LED Curing Performance and Energy Efficiency 

The emerging UV LED market is leveraging all the expertise and supply chains built up within the wider LED industry to ensure a high performing reliable solution. In order to optimize curing in your application, it is important to understand the factors to consider when evaluating performance. 

Uniformity 

Uniform light is extremely important in UV LED curing systems as poor uniformity can result in uneven cure. Most UV LED lamps are capable of light uniformity, ProPhotonix LED lamps can help maximize it through custom LED substrate and optical design. Chip-On-Board LED technology allows a higher packing density resulting in higher intensity & greater uniformity for the curing system. 

Irradiance 

Irradiance, which is the measure of exposure per second on the target surface, is denoted by light intensity and is commonly expressed in watts/cm2. On the other hand, the dose of light energy at the curing surface is measured as radiant exposure (intensity x time) and quantified as joules/cm2. Measuring both the irradiance and dose and achieving a balance between the two is crucial in ensuring that curing conditions are optimized, and consistent results are maintained. 

Additionally, the efficiency and effectiveness of UV LED curing systems depend significantly on their optical design, which ensures that the output generated by the system reaches the intended surface area of the target material and facilitates proper curing. Factors including direction of light, energy absorbed by in the UV curable film, and dose must be considered for an efficient optical design of UV LED curing systems. 

Consider UV LED Curing Cooling Capability 

As mentioned above, high peak irradiance and energy density are critical to UV curing, which often requires many LEDs operating at high current and voltage levels. This produces a lot of heat in the LEDs which needs to be removed as efficiently and as quickly as possible for maximizing their lifetime, reliability and performance. To this end, good thermal management is crucial. 

For a low intensity, cost-sensitive application requiring a compact form factor, a convection cooled lamp would be most suitable. With a higher intensity requirement, provided that the space is available to allow some increase in form factor, a fan-cooled solution may be ideal. Where space is restricted, but high intensity is a must, then a water-cooled solution may be required. 

Assess UV LED Curing Compatibility and Cost 

Compared with traditional lamp systems, LED systems offer significant benefits over the life of the lamp. Mercury lamps have short lifetimes and so require frequent replacement. LEDs allow instant-on/off, resulting in lower operating costs and have extended life which reduces maintenance costs.  

For bigger UV LED setups, replacing the entire lamp can be expensive and cause production delays. A solution to this is to use stackable or modular lamps. Stackable lamps can be put next to each other, creating a larger unit. Each lamp can be powered separately or connected to a shared power supply. Modular systems are similar but are designed to be part of a complete setup and can’t work independently. Both options save costs and are great for different lengths. 

Return on Investment (ROI) 

The ROI is a measure of an investment’s efficiency and can be calculated by dividing the benefit of the investment by its total cost. ROI reflects the profitability of a project. When calculating ROI for an investment in UV LED Curing systems, it is important to consider reduced downtime, increased energy efficiency and flexibility. 

Conclusion 

UV LED curing systems offer new capabilities that cannot be achieved with conventional curing technology. They offer reduced operating costs, highly efficient energy consumption, lower maintenance costs, longer lifetimes, low production downtime, increased operating efficiency and enhanced control capability. 

However, before proceeding with a UV LED curing system it is necessary to evaluate compatibility with specific application requirements for the best results. With more than two decades of experience in designing and manufacturing LED solutions for OEMs worldwide and over 15 years of experience in working with UV LED solutions, ProPhotonix’ team has the experience and expertise to work with you through a customer-driven project process, delivering a reliable, complete UV LED curing solution. 

The post How to Select the Right UV LED Curing System for Your Business appeared first on Prophotonix.

When the LEDs’ intense peaks are optimally matched with the absorption profile of a photoinitiator, they cause the rapid curing of materials.

UV Curing, UVA, UVB, UVC, And UVV Wavelength Ranges

What Is the Difference Between UVA, UVB, UVC, and UVV?

The ultraviolet region covers the wavelength range from 100nm to 400nm.

UVV covers the range from 395nm to 455nm. UVA is the region typically used for UV curing applications and ranges from 315nm – 400nm and are the most widely used LEDs today. UVB is the range from 280nm to 315nm and UVC is the range from 100nm to 280nm. UVC LEDs are a relatively new technology that is rapidly improving and is predominately available from 265nm to 285nm. UVC LEDs cure the top surface very well but are not as effective as UVA wavelengths at curing into the bulk of a material.

What are the Different UV Wavelengths?

In UV LED curing applications, the typical wavelengths used are 365nm, 385nm, 395nm, and 405nm.

Select the most effective wavelength for a UV Curing LED system.

Selecting the most effective wavelength for a UV LED Curing system is critical in curing applications as the optimum wavelength decreases curing time and improves the overall quality of the cure. For example, while 365nm light may be the optimum wavelength to cure based on the target materials absorption profile, 395nm may produce a better curing result due to the efficiency differences between 395nm and 365nm LEDs.

In recent years, LED technology has advanced in both output power and available wavelengths. Working closely with a UV LED curing systems manufacturer will help to identify the most effective LED solution for your application.

UV Curing Applications

UV LED curing systems are now the technology of choice across a wide range of applications including:

• Printing
• Industrial Printing
• Digital Printing
• 3D Printing
• Coatings Applications
• Adhesives

Understanding UV Curing

To learn more about UV LED Curing systems, discover the COBRA Cure FX Series, visit our dedicated blog section on UV LED Curing Systems or contact our team for free expert advice on UV Curing systems.

The post What wavelength is used for UV curing? appeared first on Prophotonix.

Flexible Form Factors & Easy Integration

LED technology enables much more compact UV lamps than traditional technologies would allow. LEDs are also more flexible as they can be implemented into various form factors utilizing LED packaging methods such as Chip-on-Board LED technology. This LED technology allows for extremely high density, powerful and uniform light from compact illuminators.

ProPhotonix COBRA Cure FX Series offers multiple mounting options for easy installation into adhesive curing applications.

Sustainability and Costs

LED technology is a more environmentally friendly technology than traditional technologies because it emits no harmful UVC, does not contain mercury, and offers much longer lifetimes reducing lamp replacement cycles and downtime. ProPhotonix UV LED lamps are warrantied to last 20,000 hours. In addition, UV LED lamps reduce operating costs due to lower energy consumption.

Stability

The light output of an LED light can be kept stable over time using electronic software control.

Instant- on

LEDs are instant-on and unlike traditional technologies require no warm-up time. The lights can easily be configured to flash or pulse depending on the application requirements without impacting on the lifetime of the lamp.

Heat sensitive components

LEDs generate very little heat onto the target area making this technology ideal for heat-sensitive components.

The post The Advantages of UV LED Curing for Adhesives Curing appeared first on Prophotonix.

This post provides an overview of Irradiance and Energy Density (Dose) in UV Curing applications. For more detailed information, download our new whitepaper “The Impact of Irradiance and Energy Density in UV LED Curing Applications” here.

What is Irradiance?

Irradiance is defined as the total radiant power per unit area [W/m²]. Irradiance will vary slightly across a cure surface and UV LED curing system manufacturers will typically quote peak irradiance (the point of maximum irradiance) for their products.

What is Energy Density?

Energy Density (often referred to as dose) is measured in units of joules per square centimeter and defined as the irradiance received for a specific time.

UV LED System Design

In practice, it is the combination of both irradiance and energy density working together that provides a successful curing solution. The new whitepaper examines the relationship between irradiance and dose through small changes to an example system to help to explain the differences in specifications between UV LED system manufacturers’ designs. It examines UV LED System window width, dwell time, working distance, and irradiance and energy density limitations as well as the measurement of irradiance and energy density.

New Whitepaper: “The Impact of Irradiance and Energy Density in UV LED Curing Applications”

With more than 15 years of experience in UV LED Systems, ProPhotonix has recently released a whitepaper examining the Impact of Irradiance and Energy Density in UV LED Curing Applications. To learn more about irradiance and energy density, download the whitepaper.

The post About Irradiance and Energy Density in UV Curing Applications appeared first on Prophotonix.

Industry Leading Dose enables increased line speeds and new applications.

COBRA Cure FX4 offers industry leading energy density through a unique design starting with the LED chip. The product includes high-density Chip-on-Board LED arrays and a wide 40mm window ensuring uniform UV light and maximum dose without any compromise on lifetime.  A COBRA Cure FX4’s high energy density can enable faster line speeds as well as the use of a wider range of substrates. It will also allow specifiers that have yet to convert to UV LED lamps due to insufficient optical power to unlock the advantages of a UV LED solution. The option to configure for multiple wavelengths has been integrated into the product.

Intensity and Dose

UV curable media requires both a minimum amount of intensity to initiate the curing process and a minimum dose for an effective, total cure. With COBRA Cure FX4, the intensity and dose level has been optimized to produce an ideal cure offering equipment manufacturers the opportunity to gain a competitive edge.

Form Factor reimagined to provide a complete solution

The unique form factor of the COBRA Cure FX4 integrates an airflow which avoids the need for any ancillary ducting or valuable space for clearance. To ease installation, the team has also integrated an aluminum T-slot profile into the product providing simple mounting options. The COBRA Cure FX4 is available in 75mm module segments up to 2m in length with high uniformity (>= 95%) across the entire length of the lamp.

The product offers a complete, cost-effective solution for high power UV LED curing needs.

Advantages of UV LED Systems

COBRA Cure FX4 offers all the advantages of a UV LED based system including vastly improved lifetime, reduced maintenance costs, significant energy savings, and with no ozone emissions or mercury content, a more environmentally friendly solution than traditional UV technologies. In addition, the ‘cold cure’ offered by LED-based systems is ideal for heat sensitive material.

COBRA Cure FX4 Applications

The COBRA Cure FX4 delivers market leading energy density offering a compact, complete solution for small to large format digital printers as well as high speed, single pass industrial print or coatings applications.

The post New High Energy Density UV LED Curing System appeared first on Prophotonix.

Form Factor Considerations

For applications with tight space requirements, UV LED curing systems should be considered over traditional technologies due to the compactness of LED lamps.UV LED curing lamps can be customized in a variety of different ways to best support your application. There are two major considerations in form factor specification: cooling and modularity. The options for cooling are convection, fan-cooled or water-cooled. The modularity options are standalone, stackable and modular. Determining the best option for your application will mean balancing performance, cost and complexity.

1. Modularity, stackable or standalone

Standalone refers to systems utilizing just one lamp for an application. Stackable means that LED lamps are placed side by side, i.e. 4 x 75mm lamps are used to make 1 x 300mm light. Stackable lights can operate independently of the lamp array and have seamless illumination between modules. Modular lights are also stacked, but unlike stackable lights, a modular lamp is a complete system and individual modules cannot operate outside the modular structure. Standalone is best for applications where the target cure area is stationary and the UV LED lamp moves in two dimensions on a rail, such as desktop 3D printers or flatbed printers. A stackable option may be cost-effective for applications that require lights with varying lengths such as conveyor belts. Modular systems are best for systems that require long lights (greater than 1m).

COBRA Cure FX3 Modular UV LED Curing System

2. Cooling Considerations

The cooling method used in a UV LED lamp is dependent on what type of intensity is required for your application. For instance, low-intensity applications can utilize convection cooled lamps whereas high-intensity applications require fan-cooled or water-cooled solutions for temperature regulation.

Convection cooled lamps can provide a cost-effective solution for low power applications. Most applications, however, will require higher intensity levels and UV LED lamps will require fan or water cooling systems. These active cooling systems provide greater reliability. Fan-cooled systems will require a larger form factor due to the fan but unlike water-cooled systems, fan-cooled UV lamps do not require chillers or any ancillary equipment. Water-cooled systems can provide high intensity but, due to the requirement of a chiller, are generally more expensive than fan-cooled systems.

Safety and Environment

UV LED systems are also safer and more environmentally friendly than traditional UV lamps. They are safer to work with as they do not emit ozone that can cause health and safety concerns for workers. As LEDs do not generate excess heat, they can be operated on heat-sensitive substrates that may have been damaged by the high temperatures of mercury lamps. They also do not contain mercury which means that heavy metal disposal is not required.

System Validation and Control Requirements

System validation testing is essential as small application-specific nuances can create variation in system performance. Different ink formulations, for example, should be tested as they may not respond as expected.

Control requirements are easily configurable as LEDs are digital technology and can be factory set to a number of configurations. Lamps can be supplied that run continuously, flash over predefined periods, or can be dimmed. Intensity profiles and device monitoring, such as short circuit monitoring, can also be factory set. LEDs are compatible with many communication protocols including Ethernet and analog control.

Reliability and Lifetime Considerations

Reliability and lifetime are key considerations when specifying a UV curing lamp. LED technology offers much longer lifetimes than traditional technologies. The output of LED lamps degrades slowly over time and UV LED lamps are usually measured as L90 or L80. A lifetime of L90, for instance, indicates that the light output will reduce to 90% of its maximum intensity in a minimum of 10,000 hours.

The design and manufacture of UV LED curing lamps will also impact the product lifetime and reliability. ProPhotonix designs UV LED lamps for reliability and quality. All products are validated through in-house DPMEA and manufacturing FMEA. Our facility is ISO-certified and our products are ROSH-3 compliant and CE and UL certified.

Cost of Ownership

When evaluating UV LED curing systems, it is important to consider optimization to minimize initial costs, but also to consider the total cost of ownership. Some cost advantages in comparison to traditional UV lamps are:

• Reduced operating costs due to efficient energy consumption
• Lower maintenance cost – the longer lifetime of LEDs means less production downtime
• Increased operating efficiency due to LEDs digital technology providing enhanced control capability

For more information on Specifying a UV LED system, download the whitepaper. If you have any questions about your application, please contact us for more information.

The post UV LED Curing System Specification: Form Factor and Other Considerations appeared first on Prophotonix.