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www.phoseon.com
The State of UV LED TodayMichael Beck
Phoseon Technology
Presented to the ASC ConventionApril 4, 2017
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Phoseon Technology
ISO 9001: 2008 Certified
Americas
EuropeMiddle East
AfricaAsia
Pacific
Coverage
World-wide support
100% LED focused
Over 250 Patents
LED Pioneer since 2002
Over 65,000 units shipped
HQ in Portland, Oregon USA
Supply chain control
Company
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Initial Market: UV LED Curing
UV INKSUV COATINGS
Industrial
Cables
Wood
Displays
Digital Inkjet
Flexographic
Screen
Offset
Enabling New Capabilities & Processes Worldwide
UV ADHESIVES
Displays
Electronics
Speakers
Medical
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UV LED Adhesive Applications
UV LED curing is ideal for adhesive applications providing accurate, safe, and high quality adhesion
Consistent, reliable, repeatable UV output
LabelsPlastic & Glass
Food
Beverage
Pharmaceutical
MedicalSyringes
Catheters
Endoscopes
Hearing Aids
IndustrialElectronics
Fixtures
Tile
Concrete
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Conventional UV vs. UV LED
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Industrial UV Energy SourcesMicrowave
(1970s)Voltage Arc/Electrode
(1940s)UV LED(2000s)
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A solid-state semiconductor device that produces light when an electrical current is allowed to flow from the positive (p-type or anode) side of the circuit to the negative (n-type or cathode) side
This is called the ‘p-n junction’LED output has increased over time, but it’s more of the Array, Optics, and Thermal management design that has allowed an increase in UV Irradiance output
LED Basics
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UV LED vs. Conventional Lamps
Lifetime (on-time) > 20,000 hours 500-2,000 hour bulb life
Environmental Mercury FreeOzone Free
Mercury WasteOzone Generation
Input Power Small (< half) Large
Maintenance Minimal Bulb replacement, reflectorcleaning/replacement
On / Off Instant Minutes
Heat 60° C 350° C
UV LED Mercury Lamp
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UV LED lamps available at 365, 385, 395 or 405nm wavelengths.Materials must optimized for narrow wavelength.
Output power can exceed 1kW of pure UV-A energy.
Wavelength Comparison
Extremely high power in narrow range
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Phoseon LED Lifetime (On-Time)UV Intensity
10K 20K 30K 40K
100%
70%
LED90%80%
Phoseon has over 50 units on long-term life test at any single time.
Testing includes various duty cycles, high-temperature, air-flow reduction, and other stress test parameters.
An example of test data
50K
Conventional Lamps: Replaced every 2,500 hours
60K Hours
> L80 @ 60,000 hours
Over 2 Million hours of SLM lifetime testing
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More consistent UV output and stable semi-conductor process.Higher quality curing and higher-yield production.
Instant-on/off and ultra-long lifetimesMore productivity, higher utilization.Elimination of consumables; replacement bulbs, reflectors, magnetrons, etc.
Lower heat-load on the curing area (no IR)Heat sensitive materials.Safer work environment .
Energy requirements reduced (50-90% reduction in energy required)Reduced operating costs.Reduced or eliminated infrastructure for exhaust, ozone removal, etc.
Environmental advantagesNo mercury disposal issues.No ozone generation.Dramatically lower carbon footprint.
Customer acceptance of UV LED has pulled suppliers and formulators
UV LED Value Proposition
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Challenges of UV LED
LED lamps are divergent sources which can impact working distance.Peak irradiance decreases with distance.Optics/reflectors can mitigate this in some situations.Light guides are generally very inefficient with UV LED.
Chemistry of adhesives may have to be optimized.Photoinitiators are limited to UV-A typesOxygen inhibition issues can require reformulation.
A large number of recent new suppliers have entered the marketplace.Low cost offerings can compromise reliability, lifetime, and consistency.Specifications/standards still being developed.IP related issues have yet to emerge.
Measurement devices (radiometers) must be designed for UV LED.
In spite of the challenges, UV LED systems have proven to be an extremely effective solution for a growing number of applications.
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Types of UV LED Lamps
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This is not radiated IR energy but energy created by electrical inefficiencies.Approximately 35% of input power is converted to useable UV output.Approximately 65% of input power is converted to unwanted heat.Cannot exceed maximum LED junction temperature and maintain lifetime.Cooling is designed to optimize the efficiency of the LEDs.Cooling can be air or water.
Thermal Management is Critical
30%
70%
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UV LED Sources – Air Cooled
Emitting Window and Semiconductor Light
Matrix (SLM) of UV LEDs
DC Power, Control, Diagnostics
Cooling FansInternal Heat Sink
Cooling Fins
365 nm @ 8 W/cm2
385, 395, & 405 nm @ 16 W/cm2
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UV LED Sources – Water Cooled
Emitting Window and Semiconductor Light
Matrix (SLM) of UV LEDs
DC Power, Control,
Diagnostics
Water Cooling Tubes
Internal Heat Sink Water Manifold
365 nm @ 12 W/cm2
385, 395, & 405 nm @ 24 W/cm2
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Water-cooled UV LED systemsAre capable of higher power.Are usually smaller and more compact.Require a recirculating chiller or heat exchange system.Water must be clean and treated with additives to avoid corrosion.Condensation is a concern if water temperatures below the dew point.
Systems spec’d for 30C better than 15C in resisting condensation.
Air-cooled UV LED systemsMore cost effective since a chiller/plumbing/water maintenance not required.Slightly less efficient than water cooled systems.
The power of some air-cooled systems now equals or exceeds water cooled systems of 2-3 years ago.
Air-cooled systems are generally larger to due fan and heat-sink configurations.
Air-Cooled vs. Water-Cooled UV LED
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The Current State of UV LED
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Performance Continues to ImproveIrradiance (Watts/cm2) and energy density (Joules/cm2) increasing.Available form factors expanding.Reliability, efficiency, and life of lamps increasing.Prices decreasingUVA is the most prevalent UV LED output.UVB and UVC Sources still not commercially viable for most applications.Growing number of UV LED lamp suppliers.
Applications are expanding rapidly.UV LED curing is commercially used for inks, adhesives, and coatings.New applications are being explored daily.Applications are switching over quicker than predicted in many segments.Formulation development tends to be end-user driven
New raw materials are being introduced to facilitate reformulation.
The Current State of UV LED Technology
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Choosing a LED Curing Supplier
LED Capability
Intellectual Property
Reliability
Service
Percentage of resources dedicated to LED?Percentage of revenue from LED?Demo units available for testing?Bare or packaged diodes for array customization?
Number of LED patents?Enable end-users freedom to operate?Worldwide coverage?
Utilize Highly Accelerated Life Tests (HALT)?Utilize semiconductor mfg and burn-in process?Long-term life testing > 60,000 hours.ISO certified? UL Qualified products?
Worldwide Sales & Technical support?Worldwide LED understanding?Root cause analysis & reporting?
The skill-sets and capabilities required for UV LED include electronics, semiconductors, optics, thermal management, packaging, mechanical and reliability engineering
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UV LED lamps are replacing conventional Hg-based UV lamps every day.The number of applications continues to grow.The challenges associated with formulation have been resolved in most inks, many adhesives and some coatings.
More work to be done but initial acceptance indicates that most obstacles are business related, not technical.
The costs of UV LED lamps have reached acceptance for many applications.
Initial investment approaching or at parity with high quality Hg systems.Compelling value proposition.Superior cost of ownership.Customer acceptance is very high. Once the transition is made, there is no reversion to conventional technology.
The customer should evaluate any potential supplier thoroughly and confirm (or separate) the claims from the data.
Conclusions
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Thank You!Questions?
Michael BeckDirector of Sales, Americas
Phoseon Technology734-576-1010