Technology Trends Driving the Adoption of UV LED Curing

The World Leader in UV LED Curing Technology
Technology Trends Driving the
Adoption of UV LED Curing
Wednesday, October 28, 2015
Industrial Sources of UV Energy
Voltage Arc/Electrode
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Microwave
UV LED
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Conventional UV Sources
Electrode
Mercury
Voltage Arc
Powered Lamp
(Electrode)
Electrical
Connection
Quartz Tube
Magnetrons
Microwave
Powered Lamp
Quartz Tube
Reflector
Mercury
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Screen
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UV LED Sources
Liquid Cooling
Tubes
(or Cooling Fans)
DC Power, Control, Diagnostics
Internal Heat Sink (Water
Manifold or Cooling Fins)
Emitting Window
and Matrix of UV
LEDs
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UV LED Sources
Direct current causes the semiconductor to emit a narrow band of UV.
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Rating Conventional UV Sources
Nominal
Power
Wattage of Unit
Length of Lamp
Typical Values
100 – 600 Watts Per Inch
Nominal Power rates power consumption as opposed to power
output. Not a relevant spec for communicating UV LED performance.
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Rating all UV Sources Accurately
!   Wavelength (nm) - distance between corresponding points of a wave.
!   Peak Irradiance (Watts/cm2) - radiant power arriving at a surface per
unit area.
Irradiance
!   Energy Density (Joules/cm2) - radiant energy arriving at a surface per
unit area.
Energy Density
Time
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UV LED Spectral Output
Materials must be formulated to take advantage of
the relatively narrow band of wavelengths.
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UV LED Optics
!   Divergent light sources.
!   Emitting angles vary.
!   Location of peak irradiance a factor of
optics (3 – 5 mm typical with flat
glass).
!   Irradiance (power density) decreases
with distance.
!   Total UV power at cure surface
remains the same with distance.
!   Uniformity at cure surface improves
with distance.
Flat Glass
Angle
Reduction
Irradiance @ Glass = 100%
Projected Area = 7.5 cm2
Power = 30 Watts
Irradiance @ 6 mm = 50%
Projected Area = 15 cm2
Power = 30 Watts
Rod Lens
View Through
Emitting Window
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UV LED Thermal Management
!
!
!
!
!
 
 
 
 
 
~30% of input power converted to useable UV output.
~70% of input power converted to unwanted heat.
Cannot exceed maximum LED junction temperature.
Cooling is designed to optimize the efficiency of the LEDs.
Cooling can be air or liquid.
30%
70%
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30% Efficient is Actually Pretty Good…
Energy efficient LED lighting fixtures provide twice the lumens per
watt of electricity than legacy metal halide fixtures.
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But where does the technology really stand
today?
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UV LEDs Continue to Increase in Output
!   365 nm UV LED systems emit:
8 Watts/cm2
12 Watts/cm2
!   385, 395, and 405 nm UV LED systems emit:
12 to 14 Watts/cm2
20 to 25 Watts/cm2
!   Laboratory LED work is being done at “much higher” levels.
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UV LEDs Continue to Increase in Output
!   365 nm UV LED systems emit:
8 Watts/cm2
12 Watts/cm2
!   385, 395, and 405 nm UV LED systems emit:
12 to 14 Watts/cm2
20 to 25 Watts/cm2
!   Laboratory LED work is being done at “much higher” levels.
!   Arc lamps emit up to 3 Watts/cm2 typically.
!   Microwave lamps emit up to 5 Watts/cm2 typically.
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UV LED Wavelengths Pushing into UVB & UVC
UV LED
Visible,
14%
Standard Mercury Lamp
;0
UV-C,
8%
UV-A,
100%
Infrared;
23%
UV-B,
30%
Visible,
14%
UV-A,
25%
365, 385, 395, and 405 nm UVA LEDs available now.
Nothing commercially available in UVB and UVC for
industrial curing today. R&D activity only.
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UV LEDs Engineered as High Tech Electronics
The construction and operation of a UV LED curing system has more
in common with a smart phone and a tablet than with
a microwave or an arc lamp.
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UV LEDs Continue to Increase in Efficiency
!   Improvements in native LED
design, manufacturing, and
quality.
!   Improvements in LED packaging
and integration.
!   Systems being properly designed
for the specific application and
more extreme operating
environments.
Leading to increasingly higher powered heads (both air and liquid),
wider product selection, and an overall reduction in total power
consumption for a given peak irradiance.
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UV LEDs Continue to Expand their Useful Life
UV Intensity
100%
90%
UV LED
80%
Conventional Lamps: Replaced every 2,000 hours commonly
70%
10K
20K
30K
40K
50K Hours
Phoseon continually operates
50+ units on long-term life
test.
Testing includes various duty
cycles, high-temperature, airflow reduction, etc.
Life cycle testing has
exceeded 50K hours.
Example of test data
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>L80 @ 50,000 hours
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Market Activity Rapidly Expanding
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Market Activity Rapidly Expanding
Printing
Segment
Innovators
Early
Adopters
Early
Majority
Late
Majority
Inkjet
Accomplished
Accomplished
Accomplished
In Progress
Screen
Accomplished
Accomplished
In Progress
Offset - Sheet Fed
Accomplished
Accomplished
In Progress
Flexo - Narrow Web
Accomplished
Accomplished
In Progress
Flexo - Wide Web
Exploring
Litho
Exploring
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Market Activity Rapidly Expanding
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More Value Delivered Every Year
!   Performance increases every year as cost decreases.
30
In-Line Monitoring
UV LED System Output
25
20
Air Cooled
Water Cooled
15
Compact Sizes
Digital Control
10
5
0
2006
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2008
2010
2012
2014
2016
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Competition Driving Improvements
Competition drives better, cheaper, and more capable lamps.
Better lamps drive end-user innovation.
New market entrants with varying capabilities. Not all will succeed.
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Impact of Mercury Regulation
!   RoHS (Restriction of Hazardous Substances)
!   WEEE (Waste Electrical and Electronic Equipment)
!   REACH (Registration, Evaluation, Authorization
and Restriction of Chemicals)
!   United Nations mercury ban by 2020.
!   Mercury exemptions in legislation
!   Due to lack of suitable alternatives
!   Large scale (factory implementations)
!   Small scale (digital printers, mobile systems)
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Now have UV LED
Likely to continue
Being reviewed July 2016
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Tips for Driving a Successful UV LED Project
!   Take ownership of the project.
!   Understand and communicate your needs.
!   Seek corporate buy-in and collaboration between all.
!   Challenge the assumptions.
!   Partners should understand one another’s technical language.
!   Controlled and supported introduction.
!   Lab demo
!   Pilot line trial
!   Production line test
!   Test and evaluate the variables at all stages
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Tips for Driving a Successful UV LED Project
!   Well-supported projects with the buy-in of the
end-user, materials partner, and proven LED lamp
partner generate success rates well over 90%.
!   Go out and look at your lamp partner/supplier.
UV LED is developing rapidly and offering desirable capability.
UV LED curing for inkjet now considered “conventional”.
In less than 10 years, nearly all UV curing will be UV LED based.
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Grasping New Technology Specs is Tough
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Thank You.
Jennifer Heathcote
Phoseon Technology
Regional Sales Manager
[email protected]
+1 (312) 550-5828
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