UV-LED Curing and the utilization of light-curable adhesives or coatings have seen considerable growth in automotive, electronics, medical, and optics manufacturing over the past years. UV-LED technology has long proven to provide more economical and consistent curing results than conventional mercury discharge lamps.
Improving cycle times in high-volume production processes while meeting the highest quality standards regarding bond strength continuously pushes the demand for high-performance light sources with superb reliability. While there are still conventional mercury discharge lamps in use, more and more curing equipment is nowadays switching to UV-LED technology. Primelite’s fiber-coupled Advanced UV-LED Light Engines take UV curing to the next level, as our solutions outperform any 200 W to 500 W mercury discharge lamp and all competing UV-LED spot light sources in every aspect: Delivering the highest intensities of customizable broadband radiation (350-470 nm) with excellent short- and long-term stability, opening up opportunities for enhanced or entirely new UV curing applications.
All of our Advanced UV-LED Light Engines for UV spot curing use high-transmission LED Light Guides to flexibly deliver the optical system output right at the application area. Perfectly matching numerical apertures make the combination of our UV-LED light sources and light guides a very efficient overall setup. Besides the advantage of being very flexible and featuring excellent transmission, these LED Light Guides are highly customizable, can be either single- or multi-pole, and in some applications, their length extends up to 20 meters.
Thanks to the wide selection of control interfaces, your automotive, electronics, medical, or optics production application will be able to integrate our UV-LED light sources. Furthermore, all our spot light sources feature field replaceable LED modules, which will your maintenance down and the daily operations more economical.
Which fiber-coupled UV-LED spot light source best fits your needs depends on your process requirements and the design envelope. Our low-footprint UV-LED exposure solution ALE/3 is already powerful enough to deliver more than two times the output of popular 200 W spot curing systems using mercury discharge lamps. And if your application cannot get enough photons, check out our Advanced UV-LED Light Engine ALE/1: It is the highest-performing UV-LED spot light source on the market, offering fantastic possibilities to build your custom broadband output spectrum. With up to five high-power and individually feedback-controlled LED Modules combined into a single optical path, the ALE/1 sets new standards in the industry for short- and long-term exposure stability.
Primelite’s broadband UV-LED light sources deliver the exact spectral composition which works best with your UV curing application. You may choose from a range of available central wavelengths (365, 385, 405, and 435 nm) and define their output intensity separately – be it the same output setting for every shot, a changing output profile during a shot, or subsequent shots with an individual spectral composition. With these capabilities, our UV-LED spot light sources can process almost every UV curable adhesive at impressive speeds and with fantastic reliability.
A fully customizable output spectrum is particularly helpful if you are searching for a UV-LED solution to replace mercury discharge lamps of manufacturing equipment in the medical or pharma field. Just replicate the spectrum of your current spot light source and keep using your originally validated adhesives or coatings.
Usually, UV-LED systems have a single central wavelength with a narrow total output spectrum. Primelite’s fiber-coupled UV-LED exposure units are more versatile, being high-power, both in mono- or multispectral configurations.
Adding near UV (NUV) in the higher spectral ranges (CWL 405 or 435 nm) to the output of your exposure unit may be very beneficial if you work with thick layers of photosensitive adhesives and coatings. Those longer wavelengths penetrate much deeper into the material and allow for a consistent full cure in a fraction of the time other UV-LED systems need.
While longer wavelengths penetrate much deeper into the UV adhesive, powerful radiation around 365 nm is often needed for tack-free surfaces. A drawback of using 365 nm exclusively is that curing speeds on the surface of photosensitive material are so fast, potentially blocking radiation from traveling further into the bonding layer and preventing a complete cure.
Because Primelite’s Advanced Light Engines perform superbly in all NUV spectral ranges, a multi-step exposure is an interesting approach. To produce both a fully cured bonding layer and a perfect surface, you could start exposing in higher wavebands (e.g., 405 nm) and finish your shot with high-intensity low wavebands around 365 nm.
|Output Power [mW]1||350-390 nm||390-420 nm||420-450 nm||Broadband|
ALE/1.2 (CWL 365/405 nm)2
|Liquid Light Guide Ø6.5||10,000||10,000||20,000|
|Liquid Light Guide Ø8.0||10,000||10,000||20,000|
ALE/1.3 (CWL 365/405/435 nm)2
|Liquid Light Guide Ø6.5||10,000||10,000||10,000||30,000|
|Liquid Light Guide Ø8.0||10,000||10,000||10,000||30,000|
ALE/3.1 (CWL 365 nm)2
|Liquid Light Guide Ø5.0||7,000|
|Liquid Light Guide Ø6.5||11,000|
|Liquid Light Guide Ø8.0||13,000|
ALE/3.2 (CWL 365/405 nm)2
|Liquid Light Guide Ø5.0||4,000||3,500||8,000|
|Liquid Light Guide Ø6.5||6,500||6,000||13,000|
|Liquid Light Guide Ø8.0||7,500||7,000||15,000|
200 W Mercury Discharge Lamp (typical values)
|Fiber Light Guide Ø5.0||1,500||1,000||1,200||5,000|
|Liquid Light Guide Ø5.0||2,000||1,500||1,700||5,500|
|Liquid Light Guide Ø6.5||3,000||2,300||2,400||8,000|
|Liquid Light Guide Ø8.0||3,000||2,300||2,400||8,000|
1Power output measured at end of light guide; deviation of ±10% possible.
2CWL of emitters: 367.5±2.5 nm, 402.5±2.5 nm, and 435.0±2.5 nm.
ALE/1 UV-LED spot light sources – the industry’s benchmark for customizable exposure spectrum with superb stability.
The ALE/3 UV-LED spot light source has an economical low footprint and is the perfect replacement for mercury discharge lamps.
Learn more about our high-transmission LED Light Guides and how their capabilities can leverage your industrial UV bonding solution.
These optical add-ons homogenize, collimate, and focus the output from our LED Light Guides and can be a low-cost way to improve efficiency.