FEATURE

ARTICLE #curing #UVLED #assembly #electronics

The combination of
high-energy UV LED sources
with the appropriate adhesive
enables increased productivity
while also providing the ability to
cure heat-sensitive materials.

UV LED Curing for Adhesives,

Sealants, and Coatings
UV LED curing technology offers lower operating costs than traditional
technologies, as well as long lifetime, enhanced system capabilities, and
environmental benefits.

U
By Jake Chaney, Regional Sales ltraviolet (UV) light-emitting diode (LED) curing technology
Manager, and Stacy Hoge, has been adopted for adhesive bonding, sealant, and coating
Marketing Communications processes in factory assembly lines throughout the world.
Manager, Phoseon Technology Adhesive chemistries that have been adapted to the UV
function to enhance curing, handling, and user control include:
acrylate/urethanes, cyanoacrylates, silicones, anaerobics, pressure-
sensitive adhesives, film adhesives, and epoxies.

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UV LED curing technology offers Figure 1. UV LED curing process.

lower operating costs, long lifetime,
enhanced system capabilities due
to being a solid-state device, and
environmental benefits associated
with safer workplace environments.
In addition, UV LED provides a low-
temperature light source for small
components that may be sensitive
to heat.

Understanding UV Curing
UV curing is a photopolymerization
process that uses UV energy to
change a liquid to a solid. Upon
absorption of the UV energy, the
photoinitiator (PI) produces free
radicals that initiate crosslinking
with binders (monomers and
oligomers) in a polymerization UV energy by applying an electric the absorption characteristics
reaction to cure or solidify the current to a semiconductor of the photoinitiators used in
coating or adhesive, usually in a device called a diode, causing it the formulation. Since current-
few seconds (see Figure 1). to emit UV energy. The specific generation UV LED emission
materials in the diode determine wavelengths are strongest at 365
Industrial sources of UV energy the wavelengths of the output, and 395 nm, photoinitiators
have long included medium- which is typically in a very narrow and other formulation
pressure mercury arc and band ± 10 nm. Figure 2 (p. 54) components should be selected
microwave-powered lamps, as well compares the output of various UV to allow efficient excitation
as the more recent LEDs. All three LED light sources with a typical of the photoinitiators at those
technologies are used to crosslink mercury arc lamp. UV LED light wavelengths.
inks, coatings, and adhesives in sources are provided in single
a wide range of manufacturing wavelength configurations, typically Benefits
processes. Both arc and microwave centered on a specific wavelength, UV LED curing embraces many
curing technologies rely on the ± 5 nm. This near-monochromatic of the advantages of traditional
vaporization of mercury within a distribution requires new chemical UV curing for manufacturing
sealed quartz tube containing an formulations to ensure proper processes, offering advanced
inert gas mixture. Mercury lamps curing of adhesives and coatings. capabilities beyond traditional
require toxic mercury disposal and mercury UV curing. First, UV
produce ozone gas that needs to be To achieve efficient and LEDs do not generate any infrared
extracted by ventilation. effective UV curing of an output that is translated into heat.
adhesive or coating, the This is extremely important on
UV LEDs are solid-state formulator seeks to match the manufacturing lines where the
semiconductors. UV LED generates UV lamp spectral output with introduction of heat changes the

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FEATURE ARTICLE

chemical properties of the adhesive or coating. In and hearing aids often benefit from UV curing
these cases, heat can lead to material warping, lack of technology because it offers better uniformity, low
adhesion, and eventually scrap. UV LEDs are a “cool” heat, instant on/off capability, and long lifetime. UV
light source; the only heat involved is due to UV energy LED curing solutions are also suited to ammunitions
being generated. production for waterproofing, adhesive bonding,
sealing, and coating. The UV LED curing of external
The second major improvement is process stability. ammunition sealants can make bullet pull strength
Manufacturing companies need consistent, stable more consistent, thereby improving performance
output. Traditional UV bulbs degrade over time, which and accuracy. Example ammunitions-related
means their UV output was not keep stable. UV LED applications include: external ammunition sealing (i.e.,
provides stable UV output consistently over time, waterproofing); igniter, fuse, and detonator UV sealing;
leading to better process control and stability. specialty UV coatings and primers; blank ammunition
sealing; shot shell crimp sealing; and tip color coding.
Applications
UV LED curing technology is ideally suited for UV LED is also a curing solution for automotive coating
electronic assembly applications. The combination applications because it provides near-instant curing
of high-energy UV LED sources with the appropriate of functional and decorative coatings. The lightweight
adhesive enables increased productivity while also materials used in today’s automobiles benefit from the
providing the ability to cure heat-sensitive materials. low temperatures enabled by UV LED technology. The
Many electronics manufacturers utilize UV LED curing automotive industry utilizes UV LED curing solutions
in the production of products such as touchscreens, for forward lighting, tail lenses, interior and exterior
mobile phones, micro-speakers, and hard disk drives. trim components, and body panels.

Adhesives used in medical applications such as Adhesive curing is utilized in industrial-grade bonding
syringes, catheters, IV delivery systems, endoscopes, for a variety of materials. Industrial processes require

Figure 2. Comparison of the output of a various UV LED light sources with a typical mercury arc lamp.

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products that can work in tough, sometimes harsh with less damage to heat-sensitive components.
manufacturing environments. Industrial UV LED In addition, UV LEDs are highly efficient, offering
curing capabilities include solar panels, wood/plastic significant energy cost savings. They require very
coatings, thin films, bottle processing, aviation, little space, making them easy to integrate into small
automobiles, and many others. spaces. Since UV LEDs produce no ozone emissions or
hazardous waste concerns, they are an environmentally
LED technology minimizes the friendly and safe UV curing technology.
heat load to the work surface, Adhesive and coating suppliers have formulations
allowing for capability with available for use with UV LED curing that are easy
heat-sensitive applications. to handle and apply in the precision, high-speed
processes that are so common in manufacturing.
LED Lifetime and Reliability When looking to improve yield rates through higher
If architected correctly, LED light sources can have productivity and reduced scrap, manufacturers should
exceptionally long lives. LED technology minimizes the consider UV LED curing technology. ASI
heat load to the work surface, allowing for capability
with heat-sensitive applications. The long lifetime,
instant on/off control, and consistent UV output can For additional information, visit www.phoseon.com.
improve process variation and control. Similar to the
lighting industry, LED curing technology has been
proven to be extremely reliable.

Even though LED technology is reliable, it is important

to keep in mind that LED light sources are not created
equally. Suppliers have significant architectural and
implementation decisions that impact their products’
performance. The ideal end result will be a LED High-Performance
curing system with optimized LEDs, arrays, optics, Specialty Additives
and cooling for a specific application. Knowing how for Your Applications
to characterize the performance allows the user to
identify the best overall system to meet their needs.
Marketing under the brand names Wingtack®,
While traditional mercury lamps may last up to 3,000 Ricon®, Ricobond®, Dymalink®, Cleartack®,
hours, properly managed LEDs will last over 50,000 Poly bd®, and Krasol®, our resins are known for
hours. If the light sources are not cooled properly, consistency and quality our customers trust.
however, they will have a much shorter lifetime and
will be less reliable. Before choosing an LED supplier, Contact us to learn more
ask for data on the lifetime of their lamps to make sure www.crayvalley.com
they are proven to be reliable.

Improving Manufacturing Processes

UV LED curing offers manufacturers higher yield rates
and productivity due to a consistent and stable process

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