Spot curing applications in the automotive, electronics, optoelectronics, and pharma industry.

UV-LED Curing and the utilization of light-curable adhesives or coatings have seen considerable growth in automotive, electronics, semiconductor, pharmaceutical and optics manufacturing over the past years. UV-LED technology has proven to provide faster, more consistent, and more reliable curing results.

Challenging cycle times in high volume production processes while meeting high quality standards concerning bond strength is continuously pushing the demand for extremely reliable high-power light sources. While there are still conventional mercury lamps in use, more and more curing equipment is nowadays switching to UV-LED technology.

Primelite’s UV-LED Light Engines take UV curing to the next level. Its feedback controlled high-intensity output easily outperforms 200 W and 500 W mercury discharge lamps as well as other available UV-LED systems in every aspect. ALE/1 systems were developed to provide extreme intensities of up to 95,000 mW/cm² of multispectral radiation (broadband spectrum 350-470 nm) while assuring the highest process stability with its feedback-controlled output. Achieving these intensity levels open up opportunities for enhanced or entirely new applications. The ALE/3 systems are super-compact light-guide coupled LED light sources reaching best-in-class performance. Its innovative thermo-electric cooling system guarantees hassle-free operations with little maintenance need and an extended lifetime.

Primelite Advanced UV-LED Light Engines for Curing Applications
Primelite Advanced UV-LED Light Engines for Curing Applications

The use of liquid light guides, potentially in combination with additional optics, gives you maximum flexibility regarding system integration and setup. Extended service life and low operating costs due to low energy consumption and limited costs for maintenance and spare parts characterize our UV-LED exposure solutions.

The Power of Multispectral Curing

Usually, UV-LED systems are monochromatic, only featuring a narrow output spectrum. With our ALE/1 UV-LED exposure unit, you have the possibility for multi-wavelength setups. The ALE/1.3 (365/385/405 nm) is especially suited for advanced curing tasks with thick layers of photosensitive material. NUV radiation in the higher spectral ranges (around 405 nm or 435 nm) penetrates deeper into the adhesive, while shorter wavelengths (around 365 nm) cure the surface layer. A 365/405 nm dual wavelength setup is also available for the ALE/3.

Primelite Advanced UV-LED Light Engines for Multispectral Curing Applications
Primelite Advanced UV-LED Light Engines for Multispectral Curing Applications

With our flexible, multispectral light sources, you have an optimum fit for a variety of adhesives and coatings. Furthermore, our broadband output provides you with higher intensity levels for quicker and even more reliable curing. This fact might allow you also to cure chemistry that usually needs UVC and does not work well with monochromatic UV-LED systems.

To make the most out of the multispectral modularity, we have created a built-in control feature – the “Power Matrix”. This feature allows for flexible exposure management per wavelength (see figure below) to create a customized multi-phase curing process.

Primelite Advanced UV-LED Light Engines: Power Matrix
Primelite Advanced UV-LED Light Engines: Power Matrix

Exemplary Industrial Applications

There are already multiple industrial applications which profit from reduced cycle times, increased throughput, and efficiency as well as excellent process stability based on our UV-LED light sources. Investment amortization for most of these high-value processes is below one year.

Pharma/Medical industry: Needle bonding

Fully automated production line for pen needles

Replacing 200 W mercury arc lamp with UV-LED

System: ALE/1.3+ (365/385/405 nm)

Main benefits and motivation:

  • Less need for quality assurance
  • Highest reliability of complete cure
  • Hassle-free (long service life, no lamp exchanges)

Automotive industry: Curing of optical sensors

Fully automated production line for assembly of LIDAR systems

Replacing monochromatic LED system

System: ALE/1.3+ (365/385/405 nm)

Main benefits and motivation:

  • Throughput & less non-conformance
  • Improved material performance

Electronics industry: Conformal coating

Conformal coating line for electronics

Spot light source additional to UV-conveyor

System: ALE/1.2+ (365/435 nm)

Main benefits and motivation:

  • Selective curing of small areas (e.g. curing under components)
  • Curing directly after dispensing to decrease process time and create structures

Micro-optics: Uniform area curing

Fully automated production line for camera lens systems

Replacing monochromatic LED system

System: ALE/1.3+ (365/385/405 nm)

Main benefits and motivation:

  • Throughput
  • Bonding stregth
  • High output stability und uniformity

Usually, LED-arrays are used to expose larger areas with UV-radiation. However, light sources coupled to highly flexible light guides are the tools of choice, when it comes to curing larger areas while having tight restrictions on the design envelope. To achieve sufficient intensity and excellent uniformity on the exposure plane, you need a high power spot light source. In combination with our performance optics, our fiber-coupled ALE/1 UV-LED spot light source provides you with ~1,500 mW/cm² on an area of 30X30 mm (working distance: 120 mm).

For more information on the product properties, technical concept and specifications of our systems please see Advanced LED Light Engines.

Highlights – Why ALE/1 and ALE/3 for UV-LED Curing and Exposure

  • Increased throughput and time savings with the most powerful output of any UV-LED spot light source available (up to 30 W)
  • Novel curing processes with a customized spectral composition of multi-wavelength setups (365/385/405/435 nm)
  • Easy integration of intense optical radiation in new and existing configurations with our fiber-coupled UV-LED light source
  • Unprecedented process stability based on semiconductor industry standards (closed-loop feedback)