sgia 2017 eit 2017 eit... · il uva 250-415 eit nm uva 320-390 nm speaking the same language...
TRANSCRIPT
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Solving UV Curing Mysteries with Measurement
Jim Raymont
Whodunit? Whodat?
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UV Can Be Mysterious Unless You Understand It• Cannot see it with the visible eye • Wavelength is a nanometer (nm)-a billionth of a meter • Reduce UV mysteries and process variables to
increase profit
• Ask questions as we go • Will share this presentation as PDF • Here to help during the SGIA show (Booth 2800)
Solving UV Mysteries
Anything that you can measure, you have a better chance of controlling. Things that you do not measure become the cause of mysterious problems
Larry Goldberg-Beta Industries
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Producing a large amount of product before detecting a problem.
UV Curing-Crime Scene
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Round Up The Usual Suspects
Suspect 1A: The Formulator
Suspect 1B: The Equipment Supplier
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� Abrasion Resistance
� Scratch Resistance
� Chemical Resistance
� Hardness
� Weatherability
� Non-Yellowing
� Flexibility
Please Describe the ……..
� Tensile Strength
� Gloss
� Coating Viscosity
� Film Thickness
� Ability to Over Coat
� TBD
� TBD
What properties are formulation driven?
What properties are process/UV source driven?
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The UV Process
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What if the cake mix only gave you the time?
• 350° X 30 = 10,500
Equal Degree Minute Options
• 700°F for 15 minutes?
• 175°F for 60 minutes?
Cake: Bake at 350°F for 30 minutes
The UV Process-Analogy
Oven Temperature ( °F) is similar to Irradiance (Watts/cm 2)
Bake Time (Minutes or seconds) is similar to Energy Density (Joules/cm 2)
Not Specified: Oven Type
Changing the Cake Process Window
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Speaking the Same TerminologyIrradiance (Intensity)• Expressed in watts or milliWatts per square centimeter (W/cm2 or
mW/cm2)
• Total radiant power of (all) wavelengths passing from all incidentdirections onto an infinitesimally small area (cm2)
• Depth of cure, penetration through pigments and opaque colors, adhesion to the substrate
Energy Density (Dose)• Expressed in Joules (J/cm2) or milliJoules (mJ/cm2) per square
centimeter
• Incorporates time as part of the measurement
• One watt for One second = One Joule
• Area under the irradiance curve
• Often the only UV exposure guide number supplied
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Speaking the Same Terminology
Time
Peak Irradiance
Communication
• Process Development
• Transition to Production
• Production
• Within a company
• With Supply Chain
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IL UVA
250-415 nmEIT
UVA 320-390 nm
Speaking the Same Language
Broadband Instrument Responses • Instrument Bandwidths are not defined and vary from manufacturer to
manufacturer and how they are specified• EIT UVA 320-390 nm, Full Width Half Max (FWHM), CWL 365 nm• IL UVA 250-415 nm CWL 365 nm
Broadband UV Spectrum• UVA: 320-390nm “Black light”, UV Inks, adhesion• UVB: 280-320nm “Toughness” , skin response• UVC: 200-280nm, germicidal (254 nm), surface cure, tack, chemical or
scratch resistance• UVV: 395-445nm, opaque/white, thick coats, adhesion, depth of cure
UV LEDs Discussed Later
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“I am loose and tight
in all the
wrong places”
Process Window
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• The range in which a process will work with the desired results
– Adhesion, hardness, flexibility, gloss, texture, stain or scratch resistance, chemical rub, cross hatch, abrasion rub, color ID, registration
– Often a compromise
• Invest before production & confirm when things are working!
– Starting guidelines from formulator?
– Define your lower limits and document the readings
– Increase line speed/decrease applied power until you undercure, note readings and cushion by 20%
– Upper limits?
• Monitor your readings by job, hour, shift or day as required to maintain quality
• Establish your process window during the design/development phase and start monitoring from day one in production
Process Window
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Variables:
• Line speed
• Lamp distance
• Lamp output
• Bulb Type
• Source Type
• Coating
Process Window
• Starting Point: Formulator Guidelines
• Testing can define a process window
• Lab testing is less expensive than production testing or
no process window
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Stop!Undercure Limit
Caution 20% Undercure Buffer Range
Normal Operating Window
Over cure or over temperature ?
Process Window
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We can’t ask a UV lamp or a power supply to
confess, but we can gather evidence using
other means…
Gathering UV Evidence
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“ Did you perform the maintenance? Did You?”
Gathering UV Evidence
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Gathering Evidence
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Gathering UV Evidence
• Right Tools?
• Right Tests?
• Right Expectations?
• Documentation?
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=
Gathering UV Evidence
Gather and preserve evidence to use it
for when conditions change
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Date
Line Speed Dwell Time
FPM/RPM
UV System: North Line Lamp: 2
Ind. Actual. PowerWPI
Hour Meter
Irradiance(W/cm 2)
Energy Density (J/cm 2)
10/9 25 22 400 780 0.859 1.45
For each UV lamp system• Hour meter • Indicated vs. actual process speed• Power settings (WPI, Amps)• Irradiance (W/cm 2)• Radiant Energy Density(J/cm 2)• Lamp matched to chemistry• Focus/Reflector condition• TBD
Preserving UV Evidence
Poor chain of custody
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Focused
lamp
Time in seconds
UV
W/c
m2
Non-Focused lamp
UV
W/c
m2
Time in seconds
FOCUSED
858 mW/cm2
2096 mJ/cm2
NON-FOCUSED
290 mW/cm2
1707 mJ/cm2
Dimensional Curing
Gloss Control
Distance Change-Same lamp
Profiling Radiometers
• Profile helps determine
focus of system and
tracks changes
• Lamp types
• Break down multi-lamp
systems
Time in seconds
UV
W/c
m2
Gathering UV Evidence
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A typical Irradiance Profile
Differences in:• Irradiance values• Lamp Types• Focus of Lamps• Speed collected
Gathering UV Evidence
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Gathering UV Evidence
In God we trust, all others bring data Dr. W. Edwards Deming
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Gathering UV Evidence
• What Data (Evidence) Is Needed? • Consistent Data Collection Techniques• Fooled by the Equipment?• Do not contaminate the crime scene or
measurement tools
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Gathering UV Evidence
Ref ReadingsUnit Readings % Deviation
Unit Power Puck II
Power Puck II
s/n 15678 17654Speed (f/m) 25 feet/min 25 feet/min
UVA mJ/cm2 mW/cm2 mJ/cm2 mW/cm2 mJ/cm2 mW/cm21 109.000 450.000 99.000 445.000 -9.17% -1.11%2 105.000 442.000 103.000 461.000 -1.90% +4.30%3 104.000 460.000 109.000 439.000 +4.81% -4.57%
Average 106.000 450.667 103.667 448.333 -2.09% -0.46%% STEDV 2.496% 2.001% 4.855% 2.537% 7.142% 4.488%
Repeat for other UV bands
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A Scandal in Bohemia
Analyzing the UV Evidence
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Inspector Jacques Clouseau: It's amazing how he fell perfectly into
the chalk outline on the floor.
Ponton: I think they drew the outline after he was shot.
Inspector Jacques Clouseau: Ah! We must be working with some
kind of mastermind!
My Best Cases
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Cases of Absent Minded Staff
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Human Error …
Unit was sent through UV system upside down
Temperature Reading
UV Readings
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55” (140 cm) bulb
Irradiance mW/cm2 Data collected 3/24/16
Band Left Center Right Highest Delta
UVA 797 983 635 35.4%
UVB 713 888 573 35.5%
UVC 200 257 167 35.0%
UVV 612 757 492 35.0%
Energy Density mJ/cm2
UVA 243 282 234 17.0%
UVB 206 239 195 18.4%
UVC 58 68 55 19.1%
UVV 231 264 222 15.9%
Arc lamp performance-Data
Bulb not installed correctly in UV system
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Graphically display UV across width of bulb
Arc Lamp Performance-Graph
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Instrument Care
• Radiometers work better when properly maintained
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Optics & Sensor Care
• Optics work better when properly maintained
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Irradiance W/cm2 Data Collected 3/24/16
Band Before After Difference
UVA 1223 983 -19.6%
UVB 1066 888 -16.7%
UVC 277 257 -7.2%
UVV 889 757 -14.9%
Energy Density J/cm2
Band Before After Difference
UVA 349 282 -19.2%
UVB 284 239 -15.9%
UVC 75 68 -9.33%
UVV 309 264 -14.6%
Before: Data collected with contaminated optics
After: Data collected after cleaning
UV Measurement Challenges
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• Two recommended methods:
o Lint/Detergent free wipes or IPA with cotton swab
• Advantages and disadvantages to each method
• First do no harm
• Avoid shirt sleeve, shop towel, etc.
• Avoid ‘dry’ cleaning instrument
UV Measurement Challenges
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You Tube Video Link on EIT website
UV Measurement Challenges
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The Case of the
Missing ID
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How Old Are You?
Hour Meter
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Devitrification / Clouding Mirroring
Blackening / Erosion Contaminated Airflow
Lamp Symptoms - Aging
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440mW/cm2 in the middle vs. 317 mW/cm2 at the end
How wide is your line compared to the product?
MiddleEnd
Aged Arc Lamp
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Variable: UV Energy Wavelength
Mercury
Gallium Iron
Courtesy Heraeus Fusion UV
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Variable: UV Energy Wavelength
Ratio of different bands to identify bulb type
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Line 1
Line 2
Blue
UVA
Red UVV
Profiling Radiometers• Trouble shoot two ‘identical’ production lines (Speed, bulb types)
Line Speed Changed Bulb Type Changed
UVA
UVA
UVV
UVV
The Real World: Readings
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UVA Energy Density: 537 to 487 mJ/cm 2
UVA Irradiance: 309 to 290 mW/cm 2
NEWOLD
With 600 hours of run time would you change this bu lb?
UV Sources: Spectral Output
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Change Now?
OLDNEW
UVV Energy Density: 737 to 1331 mJ/cm2
UVV Irradiance: 397 to 734 mW/cm2
UV Sources: Spectral Output
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The Case of the Misguided
Purchasing Staff
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Bulbs: Buy on Value vs. Price
Courtesy: Efsen Engineering
Hours
Inte
nsity
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Watch purchasing staff getting ‘specials’
Bulbs: Buy on Value vs. Price
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The Case of the
Missing Maintenance Team
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Neglect of UV curing system
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Dirty, damaged and improper reflectors can be
detected by their distinctive “UV fingerprints” on a
profiling radiometer.
Mystery: Bad Reflectors
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A CLEAN BULB AND REFLECTOR DELIVERS ALL THE UV SPECTRUM IN THE RANGES OF UVA, UVB, UVC
AND UVV
A DIRTY BULB AND REFLECTOR DELIVERS VERY
LITTLE OF THE UV SPECTRUM IN UVC & UVB ,
AND REDUCED AMOUNTS OF UVA AND UVV
A multi-channel radiometer allows you to compare short
& long wave ratios and identify changes
UVC: UVAUVC: UVV
Abrasion
Resistance
Toughness Adhesion Adhesion
& TiO2
Cure
Process Variables -Reflectors
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The Case of the
Overheated Lamp
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The bowed lamp (left) overheated due to a damaged
cooling system (right)
Lamp Symptoms – Inadequate Cooling
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Sagging-15 % difference in irradiance levels
middle to end
End
Middle
Diagnosing Inadequate Cooling/Airflow
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The Case of the
Restless Operator
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Mystery: Operator Error
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The effect of moving the UV housing away from the cure surface
FOCUSED
858 mW/cm 2
2096 mJ/cm 2
Changing the distance from the UV System to the substrate
NON-FOCUSED
290 mW/cm 2
1707 mJ/cm 2
Non-focused is not
always bad. Useful
for gloss control for
example
Mystery: Operator Error
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• Varying the distance from the UV source to the
substrate is a common source of process problems
• Substrate Height?
Lamp Symptoms – Distance to Part
Mystery: Operator Error
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The Case of
Unexpected Gremlins
(Mr. Murphy)
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Quantitative, routine
maintenance Real-time
status monitoring
Periodic vs. Real-Time UV Measurement
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Without an early warning system, the dipstick is useless.
Periodic vs. Real-Time UV Measurement
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• Works for applications where a radiometer will not fit or is not practical– Web– Bank of multiple lamps– Lamps high off ground
• Continuous feedback about UV conditions– Certificate of Conformance – Tight Process Windows– High Value Products
• Continuous monitoring of lamp intensity
• Communication– Percentage readings – Coordinate with absolute radiometer
When to Use?
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Sensor Locations
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Display/Conditioning Options
Panel Mount• One Sensor• Display plus 0-10V
Output
Din Rail• One Sensor, 0-10V Output
Quartz Rod
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Making a Case For
New Lamp Sources
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One Bullet Barney……
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Hg spectra modified with added materials
0
10
20
30
40
50
60
70
80
90
100
200 250 300 350 400 450 500
wavelength [nm]
rela
tive
spec
tral
rad
ianc
e
Hg Ga Fe
Mercury
Gallium
Iron
Traditional UV Source Spectral Output
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EIT Bandwidth Responses
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Images courtesy Baldwin, Dymax, Integration Techno logy, Excelitas & Phoseon Technology
UV LEDs
Wide variety of UV LED sources • Multiple suppliers with wide level of expertise,
support, finances• Match source to your application & process• Economics of source selected (ROI)
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Adoption Curve
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Adoption: Digital-Standard
Suppliers: End Users:
Courtesy
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Courtesy
Adoption: Digital-Standard
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Adoption: Digital , Custom
Suppliers: End Users:
Courtesy
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Courtesy
Adoption: Digital , Custom
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Adoption: Screen, simple
Suppliers: End Users:
Courtesy
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Adoption: Screen, Industrial
Suppliers: End Users:
Courtesy
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EIT Bandwidth Responses
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Δ = 60%
Measurement of 395 nm LED
Δ = 95%
Using UVA to measure a 385 nm or 395 nm LED
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Evaluate LED Output
• Width of the LED at the 50% Power Point
• Variations between suppliers:• Binning• Longer wavelengths• Sold as +/- 5 nm from center
wavelength (CWL)
395 nm LED array output measured on a spectral radiometer at EIT
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L395 LED Output Spectra Showing + 5nm Spread of Cp A long with Required Filter Response to Obtain 2% Measurem ent
Define the right band?
Theoretical Band
Account for variation in
the LED CWL
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Optics Design
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L395 Instrument Response
Total Measured Optical Response
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LED-R™ Series
LEDCure™ Radiometer• L395 Total Optics Response
• Single Band, Cosine Response
• Two Options: Standard & Profiler
• 40 Watt Dynamic Range
• Patented Optics Response
Suggested Operating Range L395
400 mW/cm2 to 40 W/cm2
Start Threshold
16-48mW/cm2
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LEDCure L395 Performance
Data collected at EIT February 9, 2017
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• A 395nm UV LED source was calibrated to 16W/cm² using the EIT L395.
• The UV LED source was then measured with another NIST traceable radiometer.
• The two radiometers matched to within 4% at different irradiance levels.
Data Courtesy of Phoseon Technology
LEDCure L395 Feedback
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• The EIT measurement differed from the calculated value by less than 1%.
• The other NIST traceable radiometer differed from the calculated value by more
than 13%.
LEDCure L395 Feedback
Data Courtesy of Phoseon Technology
0
1
2
3
4
5
6
7
8
9
10
11
Ene
rgy
Den
sity
(J/
cm²)
Energy Density Measurements
EIT L395 Other NIST Meter Calculated
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• Measurements at different irradiance settings were made with the
EIT L395 radiometer, and compared to the expected values.
• The L395’s linearity across a 3:1 dynamic range is excellent.
LEDCure L395 Feedback
Data Courtesy of Phoseon Technology
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LEDCure L395 Performance
LEDCure vs. National Standard
Working Distance
(mm)
Primary Standard: Integrating
Sphere(W/cm2)
LEDCure L395
(W/cm2)
Difference
5 9.01 9.23 2.4%10 7.74 7.74 0.0 %15 6.66 6.63 - 0.5%20 5.74 5.83 1.6%25 5.04 5.08 0.8%
Data Courtesy Lumen Dynamics/Excelitas
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Image courtesy Hamamatsu
UV LEDs
Future• Shorter wavelength
LEDs• Improvement in life
& power in the shorter wavelengths
• Chemistry continues to improve to reach more applications
• Dual 365 & 395 nm Source
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� Establish a baseline.
� Establish a process window.
� Make measurements routinely.
� Measure consistently. Same location, speed, device
� Document test procedures
� Use right tools
� Label & mark equipment
� Calibrate all of your tools
� Communicate & Involve Supply Chain
Crime Prevention Tips
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Jim RaymontEIT Instrument Markets
Director Sales
Member ASDPT
Want a copy of this presentation?
Send me an Email or give me a card
Open Discussion-Questions
703-478-0700
www.eit.com
SGIA Booth 2800