1. Dave Kim, Phoseon Technology

2. LEDs for General Lighting & UV Curing

3. UV Output in Practice
Wavelength (nm) – must be matched to formulation of ink, coating, or adhesive. 395 nm most typically used. 365, 385, and 405 nm also available nm in development.
Peak Irradiance (Watts/cm2) – beneficial for penetration and surface cure.
Energy Density (Joules/cm2) – promotes more thorough cure and faster line speed.
Time
Energy Density
Irradiance

4. Both LED systems below emit the same irradiance (W/cm^2)
LED system on the left emits more energy density (dosage in J/cm^2)
Phoseon units do not incorporate focusing optics that inflate irradiance
Higher energy density allows for cure and adhesion at higher press speeds

5. Irradiance vs Energy Density
Higher Power
Lower Total Energy
Higher Power
Higher Total Energy
Lower Power
Lower Total Energy
Lower Power
Higher Total Energy
Energy Density

6. Irradiance vs Energy Density
System A is 16 W/cm2 and 20 x 150 mm wide at the emitting window. Irradiance profile measures 2.34 J/cm2 in energy density with 1.2 KW input.
A and B deliver similar energy density (area under irradiance curves) but may not cure the chemistry similarly.
System B is 8 W/cm2 and 40 x 150 mm wide at the emitting window. Irradiance profile measures 2.53 J/cm2 in energy density with 1.4 KW input.

7. Nominal Power (Watts/in)
Electrical Input vs Irradiance
Product
Wavelength
(nm)
Length
(mm/in)
UV Head DC Supply Power
(Watts)
Nominal Power (Watts/in)
Irradiance
(Watts/cm2)
LED – FL400
395
450/18
4,361 DC
240 16
5,451 DC
300 20
5,775 DC
320 24
Mercury
Broad Band
5,400 AC
1 – 2
7,200 AC
400
2 – 3
9,000 AC
500
3 - 4
10,800 AC
600
4 - 5
*For purposes of comparison, all lamps are 450 mm (18”).
**Calculations do not include chillers, exhaust blowers, or make-up air. Strictly a comparison of lamp supply power and output irradiance.
***Irradiance for UV LED curing systems is specified at the emitting window. Conventional UV systems are typically at 2” from lamp head.

8. Form Factor – Scaled Lamps

9. Optics
Flat Glass
Rod Lens
External Reflector
Internal Reflector
A single row of LEDs or a narrow matrix of LEDs must be used with optics and reflectors to be effective. Typically results in less energy density.

10. Over 2 Million hours of total SLM Lifetime Testing
LED On-Time
UV Intensity
10K
20K
30K
40K
100%
70%
LED
90%
80%
50K
Conventional Lamps: Replaced every 2,500 hours
70K Hours
60K
Over 2 Million hours of total SLM Lifetime Testing

11. Intended Use & Process Window
Physical properties of final cure – drive chemistry formulation
Formulation - matched to wavelength and irradiance (Watts/cm2)
Working Distance - lamp peak irradiance or head optics selected to deliver needed irradiance at cure surface
Process Line Speed – determines needed energy density (Joules/cm2)
Plant Environment & Preference - drives cooling selection (air or water)
Mounting location – available application space / web width drives lamp form factor

12. Are UV LED curable inks for wide web and flexible packaging application safe?
Compared to traditional solvent-based inks, UV LED curable inks…
Contain little to no amount of VOCS
No venting/ducting/after burner required
Do not contain solvents including IPAs and acetate
No local city VOC emissions limit that would curtail production capacity
No explosion proof container/room to store inks required
Are not flammable, ignitable, nor emit fumes
No inhalation risks

13. UV LED Curable inks vs. Water-based inks for flexible and wide-web applications
Faster Print speeds UV LED curable inks print at much faster speeds than water-based inks and at similar levels of solvent-based inks. UV LED curable inks provide fast curing even with the most problematic non-porous substrates such as film
Press Efficiency UV LED curable inks require little to no mixing for reduced setup times and can be left in the ink pans overnight
Print Quality UV LED curable inks provide higher resolution images and colors that are truer and have more pop
Lower electricity consumption
Less ink consumption UV LED curable inks are more viscous and stronger and therefore a lower volume anilox roll can be used to save on ink $$$

14. Low migration UV LED curable inks
No need for barrier films
All the benefits of UV LED curing vs. water-based inks

15. Thank You!
Dave Kim Phoseon Technology Regional Sales Manager +1 (510)