TABLE OF CONTENTS Benefits of UV Light Curing ...................................................................................................................... Page 3 Overview of UV Light-Curing Systems ..................................................................................................... Page 4-5 Fundamentals of UV Light-Curing ............................................................................................................ Page 6 Designing a UV Light-Curing Process .........
BENEFITS of UV LIGHT CURING Light-curing technology has allowed manufacturers to lower processing costs, produce higher quality products, and eliminate the use of harmful chemicals from the workplace for over 30 years.
OVERVIEW of UV LIGHT-CURING SYSTEMS SPOT-LAMP SYSTEMS Dymax spot-curing systems provide very high intensity (3,0008,000 mW/cm2 (320-395 nm)) over a small area (typically <½", 5 mm diameter). These intensities usually result in a 0.5-5 second cure time. Dymax spot-curing systems utilize an integral timed/manual shutter and typically require little external shielding. An intensity adjustment feature aids users in both validating and controlling a UV light-curing process.
OVERVIEW of UV LIGHT-CURING SYSTEMS RADIOMETERS A radiometer is a device that measures the intensity and/or dose associated with light of specified wavelengths. UV light is, by definition, not visible and so a radiometer is required to determine UV intensity. The ACCU-CAL™ 50 radiometer is ideal for measuring the UV intensity of UV spot lamps, flood lamps, and conveyors. This radiometer measures intensity and dose in the UVA (320-395 nm) range.
FUNDAMENTALS of UV LIGHT CURING Developing a successful light-curing process requires knowledge of the following key concepts. Higher Intensity = Faster Cures – Intensity is the light energy reaching a surface per time and it is often measured in mW/cm 2. Higher intensity light (of the proper wavelengths) will generally provide faster cure.
DESIGNING a UV LIGHT-CURING PROCESS There are several factors to consider when designing a UV lightcuring process. Intensity – A well-designed UV light-curing process incorporates a curing system with excess intensity. Excess intensity provides both a safety margin and long bulb life. See page 18 “Setting Up and Monitoring a Light-Curing Process” for specific intensity and safety margin guidelines. Spectral Output – It is important to match the spectral output of the lamp to the material and application.
UV LIGHT-CURING SPOT-LAMP SYSTEMS BlueWave® 200 WITH INTENSITY ADJUSTMENT The BlueWave® 200 UV light-curing spot lamp offers the highest intensity and most user-friendly operation in the industry. The BlueWave 200 spot lamp primarily emits UVA and blue visible light (300-450 nm) and is designed for UV light-curing of adhesives, coatings, and encapsulants. With over 17 W/cm2 in initial bulb UVA curing intensity, 0.5-5 second cures are typical.
UV LIGHT-CURING SPOT-LAMP SYSTEMS DYMAX BLUEWAVE® LED PRIME UVA The BlueWave® LED Prime UVA high-intensity spot-curing lamp is designed for rapid curing of various coatings as well as adhesive bonding of metal, glass, polycarbonate, PVC, PET, and many other substrates. This simple-to-operate spot lamp emits over 15 W/cm2 of UV curing intensity and features an intensity adjustment feature from 0-100%. The BlueWave LED Prime UVA is compatible with a wide array of lightguide options (see Table 1 on page 11).
UV LIGHT-CURING SPOT-LAMP SYSTEMS DYMAX BLUEWAVE® 75 WITH INTENSITY ADJUSTMENT The BlueWave® 75 UV light-curing spot lamp is simple to operate and is designed for use with light-curable adhesives, coatings, and encapsulants. The BlueWave 75 is compatible with a wide array of lightguide options (see Table 1 on page 11). With over 9 W/cm2 in initial UV curing intensity, 1-10 second cures are typical. Bulbs used in UV light-curing spot lamps degrade with use, emitting less and less intensity.
LIGHTGUIDES for UV LIGHT-CURING SPOT-LAMP SYSTEMS LIGHTGUIDES Lightguides transmit UV and visible light from a source mounted inside of a spot-curing unit to the curing area. There are several factors to consider when choosing a lightguide. Length – Lightguides are commonly one meter long although other lengths are available. Curing Area/Intensity vs. Distance – The UV and visible light emitted from a lightguide diverges.
ACCESSORIES for UV LIGHT-CURING SPOT-LAMP SYSTEMS SPOT ACCESSORIES UV-BLOCKING EYE PROTECTION There are a number of accessories available for the Dymax BlueWave® 200, BlueWave® LED Prime UVA, and the BlueWave® 75 UV light-curing units. Please contact Dymax Applications Engineering for more information on the accessories featured below. Dymax recommends that operators using Dymax equipment wear UV protective eyewear. All Dymax eye protection blocks >99.9% of UV.
UV LIGHT-CURING FLOOD-LAMP SYSTEMS Dymax UV light-curing flood-lamp systems are ideal for light curing large parts or curing many small parts simultaneously. With intensities ranging from 75-225 mW/cm2, Dymax flood lamps are capable of curing most UV light-curable adhesives, sealants, and coatings, tack free in 30 seconds or less. These flood lamps can be incorporated into automated assembly systems or mounted onto conveyors.
SHIELDING & SHUTTERS for UV LIGHT-CURING FLOOD-LAMP SYSTEMS Dymax 2000-EC and 5000-EC UV light-curing flood lamps can be outfitted with the shutters and shielding shown below. Additional shutters, enclosures, and accessories may be available. SHUTTERS SHIELDING Turning a bulb off and on between cycles is not practical since each off/on cycle shortens bulb life and requires a 5-minute warm-up period. A shutter, however, can be used to shield a flood system between cycles.
DYMAX UV LIGHT-CURING CONVEYOR SYSTEMS The standard Dymax conveyor platform, the UVCS series, has a belt width of 12" (304.8 mm) and can be outfitted with a number of different UV light-curing systems (as shown below). Belt speed is accurately measured using an optical encoder and displayed on a digital LCD. The UVCS series conveyors are completely shielded. The Dymax 5000-EC and Fusion® F300S curing systems listed below are described in more detail on pages 12 and 14, respectively.
RADIOMETERS for UV LIGHT-CURING SYSTEMS A radiometer is a device that measures the intensity and/or energy associated with light of specified wavelengths. UV light is, by definition, not visible and so a radiometer is required to determine UV intensity. Dymax offers the ACCUCAL™ 50 for spots, floods, and conveyors. The ability to measure light intensity is useful for three reasons: 1.
UV LIGHT-CURING SAFETY Dymax ultraviolet light-curing technology has been used successfully for over 30 years. The fast cure, one-component nature of our UV light-curing technology has made it the process of choice for many manufacturers requiring a “Cure on Demand” assembly process. There are three common questions/concerns related to UV light-curing systems: UV exposure, ozone, and bright visible light.
7 SETTING UP and MONITORING a UV LIGHT-CURING PROCESS There are two parameters that must be considered to ensure a successful light-curing process, 1) intensity at the curing location and 2) cure time. Dymax recommends setting up and monitoring a UV light-curing process as follows: 1. 2. Choose a Light-Curing Material (LCM) – Select an LCM that satisfies the performance requirements of the application.
MAXIMIZING UV LIGHT-CURING LAMP PERFORMANCE There are three ways to maximize lamp performance: 1. Proper Set-Up – The first key to maximizing lamp performance is proper set-up. Reference the operation manual provided with each Dymax lamp for instructions on proper set-up. After ignition, wait five (5) minutes before use to allow the lamp to reach full intensity. Then, use the following techniques to maximize intensity at the curing location.
FREE DYMAX EQUIPMENT EVALUATION Contact your Dymax representative to initiate rental of Dymax UV light-curing equipment. The highlights of the Dymax Trial Rental/Lease program are: ■ ■ ■ ■ Two (2) weeks free evaluation and 3% per week thereafter Eight (8) weeks of rental fees are deducted from the price at purchase 50% of additional rental fees are deducted Customer pays shipping both ways © 2005-2012 Dymax Corporation. All rights reserved.
