UV Polymer Curing

UV Polymer curing is a process that uses UV light to alter the properties of a polymer, or photopolymer.  A photopolymer is the term for a polymer that responds to UV light, which is basically invisible electromagnetic radiation.  When a photopolymer, which can be a variety of resins, is exposed to the UV radiation, it will typically harden and seal, creating a strengthened surface or an unbreakable bond.

UV Polymer Curing Applications

UV Polymer curing is used in many industrial applications to instantly dry ink or to create a hardened surface without use of solvents or chemicals.  Some common examples of useful applications include:

• Adhesive Bonding

• Inks / Varnishes / Lacquers

• Decorative Glazes

• Coatings

• Label Printing

• Graphic Designs

• Disinfection of Medical Equipment

These are just a few of the many industries that are using UV lamps for curing various polymers.  There are many additional applications for UV curing, and more and more businesses are seeing the benefit of this process.  UV curing was first introduced in the 1960’s, and it is increasingly being adopted by companies as there are many advantages over prior methods of curing polymers.

Curing Lamps

There are three types of UV lamps used for UV polymer curing.  High Pressure UV (HPUV), Medium Pressure UV (MPUV), and Amalgam Lamps.  High Pressure (HPUV) curing lamps are also referred to as Metal Halide lamps, and use mercury with short wavelength outputs.  The HPUV lamps are typically used for the altering of polymers by hardening resins in many of the applications mentioned above.  Medium Pressure lamps (MPUV) are often used for water and air disinfection purposes, while Low Pressure Amalgam lamps are typically used for curing catatonic inks which are inks that are typically an epoxy based resin and respond to UV lighting.  LightSources and our European partner, LightTech, are proud to have pioneered new pellet technology for amalgam lamps.

There are so many benefits to using UV lights for curing it will be difficult to list them all.  We can begin with efficiency.  Imagine a conveyor belt full of parts passing under a UV light as they head to their next destination, possibly quality inspection or packaging.  While no one touched the parts, sprayed solvents on them, or even laid eyes upon them, they underwent a very important process.  Just by passing under the lights, the surface was hardened and strengthened, a strong scratch-resistance texture was enhanced, and any printing or graphic design needing reinforcement was just instantly dried and strengthened.

Now imagine a different manufacturer that does not use UV curing.  They must have an assembly line with people spraying solvents on the parts, requiring face masks and ventilation and still exposing the employees to harmful chemicals in the air and on the skin.  This also opens the door for human error, uneven coating, and inconsistency.

As you can clearly see from these two examples, the efficiency of UV curing is definitely one of the most valuable benefits.  This efficiency also leads to increased production speeds as several parts can be treated at once simply by passing under a row of the proper high intensity UV lighting.   Choosing to cure your parts with UV lighting will increase your output dramatically, while not requiring an investment in an increased labor force, workstation for an added process, or supplies of chemicals that are most likely harmful to the environment.

In addition to efficiency and cost savings, consistency is another big advantage of using UV curing over any other process.  With UV lighting, the amount of exposure is constant, and consistent.  There is no chance of human error in applying an outer coating unevenly on a large amount of parts.  This consistent process results in less quality issues such as internal rejects and the worst rejects of all, customer returns and complaints.   A consistent process is something that all quality minded OEM’s are searching for as consistency results in superior quality, time and again.

Efficiency and consistency are and should always be a top consideration for any production process, (both result in increased profits), but let’s not forget an even more important benefit – the health and safety of your workers and the environment.  Simply by using UV radiation to cure your parts, you are saving your employees from inhaling harmful chemicals, you are not emitting pollutants into the air, and you also do not have to worry about properly storing or disposing of such harmful chemicals.   Any chemical substance on a worksite must be handled with proper storage and disposal guidelines, while maintaining material safety data sheets on the chemical or solvent.

Not only does the increased efficiency and consistency provide an instant return on your investment and a quick increase to the bottom line, not purchasing, storing, disposing of or documenting alternative substances is also a huge savings, and instant increase in profitability.

With all of these benefits, it is difficult to imagine why a manufacturer would choose an alternative method over UV polymer curing.   Efficiency, consistency, safety, less regulations, increased profits, and last but not least – longevity.   LightSources UV curing bulbs will retain their energy output up to 90% of their end of life cycle, enhancing and prolonging all other financial benefits.  As we all know, time is money.  Less time spent processing parts, or replacing bulbs, is an immediate increased profit.

LightSources in the United States, and our European partner, LightTech, provide quality custom UV bulbs to OEM’s large and small all over the world.   If one of our standard sizes does not fit your application, contact us to see how we can assist you in providing custom built bulbs for your required process.   LightSources and LightTech are also the only manufacturer to offer universal installation.   Our lamps can be installed either horizontally or vertically while maintaining equal efficiency.  This feature is exceptionally critical when applying the UV polymer curing process to three dimensional parts, allowing an even exposure to the UV radiation reaching what were previously hidden dimensions.

LightSources in the U.S. and our strategic partner in Europe, LightTech represent the leading high-tech designers and manufacturers in the lamp industry today.  Our products are used world-wide in a multitude of applications and industries such as our UV air treatment systems that offer patent-protected, OEM-oriented solutions.  We invite you to contact us to learn more about our wide selection of lamps.

UV Glue Curing

Referred to as liquid glue, UV glue curing is a superior bonding method although this is really a polymer, rather than a glue.  This polymer is often in a silicon glue form, an epoxy, polyurethane, or other polymer that will dry clear only when exposed to UV light.  The UV wavelength is a catalyst for a photochemical reaction which causes the polymer to harden, almost instantly.  In most cases, the polymer will harden when exposed to UV light for only three seconds, although some applications may recommend exposure for ten to fifteen seconds providing optimum bonding adhesion.  This is still considerably less time required for curing polymers than other methods, providing maximum efficiency in several adhesion processes.

UV glue curing is gaining popularity over other methods of bonding such as drying or exposure to chemicals, growing at a rate of 10% per year.  Bonding with heat or drying works by evaporation, which can be inconsistent and can also take time for the inks to dry.  Chemical treatment can be costly to purchase materials, and may expose employees to harmful inhalants or respiratory contaminants.  UV glue curing is quick and consistent, providing and instant hardened surface with no harmful chemical exposure.

UV Glue Curing – A Powerful Photochemical Reaction

Whatever the polymer used, the glue will not harden until exposed to UV light.  This is advantageous over substances such as instant super glues that can stick to fingers or other areas not meant to be bonded together.  With UV polymer or glue curing, the bonding area is targeted, drying instantly only in the area meant to be bonded.  The photochemical reaction occurs when the polymer, or glue, is exposed to UV light at particular wavelengths occurring between 240 Nanometer (nm) and 270 nm and 350nm to 380 nm.

In some cases, a second layer can be applied, providing even more strength for an unbreakable bond.  This UV glue curing process can be used on almost any substrate, bonding plastic, glass, metal and wood, and even glass to glass, or any variation imaginable.  This versatile process can even be applied to three-dimensional parts, saving time and money with quick all over curing.

Where are Curing Lamps Used?

UV curing of glues and polymers is used in a vast number of commercial, industrial and even residential applications.  Some applications that utilize UV glue curing include:

• Decorating of plastic and glass

• Graphic Arts

• Printing

• Electronics

• Automotive

• Boating

• Plumbing

• Manufacturing Processes

Some common examples in commercial applications would be windshield repair or fixing leaking pipes.  Manufacturing processes include assembly lines with parts undergoing UV glue curing in automotive applications such as curing inks on knobs or buttons for interior visual parts.  The gloss provided by the UV process is superior to none, providing clear and shiny print that is resistant to scratching and staining or fading.  The ability to apply this process to three-dimensional parts is advantageous providing speed and efficiency to many manufacturing assembly lines in the automotive and electronics industry.

Endless Options with UV Curing Finishes

One big advantage to the finishes with UV curing is that it dries clear, allowing multiple layers if need be while sanding down the finish will provide an invisible ‘liquid plastic’ unbreakable bond.  Paint or stain can be applied to the finish, giving endless options for applications with various products.

Benefits of UV Glue Curing

The benefits of UV glue curing are evident just from the increased productivity.  The speed at which parts can be cured is a huge benefit, as increased efficiency equals increased profits.  Products speeding by on a conveyor belt undergoing a superior bonding process while on their way to a packing or inspection station is a big time-saver over a lengthy chemical treatment or drying station, thus reducing labor or additional process stations.

Reduced labor is an advantage, along with reduced set up time and reduced clean up time.  A UV polymer curing station would carry a small footprint, not taking nearly as much space as an alternative curing station.  Combined with the high yield enjoyed with this process, the efficiency of UV curing pays with a quick return on investment.

Improved quality is one of the biggest benefits realized with UV glue curing over other methods, as a consistent process equates to improved quality.  With UV curing there is no loss of volume or thickness as with drying methods causing evaporation.  The more consistent UV curing process also means reduced scrap, which is another goal for improved quality.

Stronger parts, with improved scratch resistance and enhanced gloss are also additional benefits with this enhanced curing process.  UV glue curing provides an unbreakable bond, with improved part visual appeal and functionality.   All of this happens with an environmentally friendly process and no harsh chemicals.

LightSources – Experts on All UV Glue Curing Processes

LightSources is the global leader in all aspects of the lighting industry, providing UV bulbs for any and all UV curing processes.  We have the knowledge and experience to provide best in class products, proven for effectiveness and delivering the exact output required for your system.  We can provide various sizes and shapes of lamps, with specialty phosphor blends, and custom ceramic bases for your new UV curing system, or adapting to an already existing UV system.

The experts at LightSources have developed patented and proprietary products, delivering innovative lighting solutions for a vast array of uses including UV curing lamps, UV germicidal lamps, lamps for phototherapy, water and air purification, tanning lamps, neon signs, computer backlighting, mini-fluorescent lamps, even lamps used in the NASA Space Shuttle, the list is endless.  Each of these applications require high performance lamps designed to deliver the optimum wavelength of ultraviolet light, providing proven, effective solutions.

With our world-wide locations and numerous partnerships around the globe, LightSources has the resources available to satisfy demanding requirements, with proven UV solutions to meet stringent quality and delivery specifications.

LightSources and our affiliated companies represent the leading high-tech designers and manufacturers in the lamp industry today.  Our products are used world-wide in a multitude of applications and industries such as our UV glue curing lamps that offer patent-protected, OEM-oriented solutions.  Please contact us to learn more about our large selection of specialty custom and standard lamps.

UV Ink Curing Systems Provide Quick Effective Results

UV Ink Curing Systems are specialty machines and equipment that use UV light to cure inks, adhesives or coatings onto various substrates.  When UV light is used at the proper wavelength, or nanometer (nm), and exposed to the specialty inks or coatings, a photochemical reaction occurs instantly drying the ink.  This UV curing occurs very quickly, providing a strengthened outer coating with a uniform finish.

Medium pressure UV (MPUV) lamps in the wavelength of 367nm to 400nm are extremely efficient in curing specialty inks, adhesives, bonds and coatings (varnishes, glazes and lacquers).  The LightSources Group provides UV lamps in the most effective wavelength for your application.

How UV Ink Curing Systems are Used

UV ink curing is used in many different commercial and industrial applications, providing an effective and efficient way to dry or cure inks during manufacturing processes.  For example, UV ink curing systems are used in screen printing machines providing an instant print and cure process all in one.  These sophisticated systems use vacuum systems to hold substrates in place while providing an all over 360° UV cure of flat or cylindrical products in many shapes and sizes.

UV lamps are used in curing systems for various industrial applications, curing inks, adhesives and coatings in manufacturing processes around the globe.  Medium pressure UV lamps can be used to cure coatings on various substrates, including plastic, glass, metal and wood.   Parts can be passed under UV lamps while on a conveyor, moving from one work station to another, while receiving a very important curing process along the way.

This efficient process eliminates the need for a labor intensive ink curing station, allowing high power UV lamps to do perform a vital finishing process.

Where are UV Curing Systems Used

UV ink curing systems are used in a wide array of commercial and industrial applications, providing a very effective curing process with maximum efficiency.  Some industrial applications for UV ink curing include:

• Marketing – any type of printing on either flat or cylindrical products for target marketing and brand awareness

• Packaging – quick drying of labeling on various packaged products including corrugated, plastic and glass

• Automotive – UV ink curing provides instant drying of interior automotive components such as knobs and buttons

• Aerospace – quick and effective curing of inks and adhesives create durable components

• Medical – UV curing provides drying and disinfection in pharmaceutical and medical applications

• Consumer Electronics – used for drying and adhesion in parts and components such as circuit boards, interior and exterior parts

• Adhesive Bonding – used in several industrial applications

• Instant curing of coatings such as varnishes, lacquers, glazes, and inks

LightSources has extensive experience providing superior UV lamps for all UV ink-curing systems used in virtually any application.  With in-depth knowledge of low-pressure, medium, and high-pressure UV radiation, our expert engineers are sure to provide you with the proper UV lamps for your application.

Benefits of UV Ink Curing Systems

There are many benefits of using UV ink curing systems over other methods such as heat curing, which can create noxious fumes and require expensive exhaust systems.  UV systems are less expensive to maintain than other systems. With high-performing UV lamps from LightSources, you will see a quick return on your investment, with long-lasting cost-efficient savings.

The photochemical reaction with UV curing happens so quickly there is minimal evaporation resulting in a consistent surface finish, compared with air and heat drying which allows for evaporation jeopardizing part integrity.  UV curing contributes to a superior quality product, satisfying customer specifications.

MPUV lamps by LightSources are ideal for high-speed production runs, where UV radiation of higher intensity is required for short exposure times.  Our lamps operate with more power, producing high currents for greater output.

The LightSources Group provides industries worldwide with high-performance UV lamps used in a multitude of applications including UV curing and UV germicidal lamps used for air, water and surface disinfection.

LightSources and our affiliated companies represent the leading high-tech designers and manufacturers in the lamp industry today.  Our products are used world-wide in a multitude of applications and industries such as our UV ink-curing system lamps that offer patent-protected, OEM-oriented solutions.  Please contact us to learn more about our large selection of specialty custom and standard lamps.

Learn How UV Light Curing Improves Your Process

UV light curing is the process of altering the properties of polymers, or photopolymers which refers to polymers that undergo changes to their molecular structure when exposed to light.  UV light emits invisible electromagnetic radiation, causing a change in properties to photopolymers. UV light will cause a photopolymer, which are a wide variety of resins, to instantly dry, harden or seal with an unbreakable bond.

UV light is used in many curing processes worldwide by industrial, commercial and government manufacturing and production companies to improve their process.  By exposing their manufactured polymer products to UV radiation, they can instantly dry ink on parts and strengthen surfaces without using harmful chemicals or solvents.  Some examples of processes that benefit from UV curing include:

• Instantly drying of inks, lacquers and varnishes

• Creating an improved adhesive bond

• Enhancing decorative glazes

• Drying outer surface coatings

• Improving graphic designs

• Screen printing

• Disinfecting of surfaces, air, and water

• Disinfecting medical equipment

This is only a short list of the multitude of benefits realized by UV curing.  As more and more businesses realize the many benefits of curing with UV radiation, there will continue to be an increase in companies adopting this superior curing method in their processes.

Types of UV Light Curing Lamps

The three basic types of lamps used in UV curing processes are:

• Low-Pressure Amalgam Lamps

• Medium-pressure UV (MPUV) Lamps

• High-Pressure UV (HPUV) Lamps

Low pressure amalgam lamps are typically used for polymer curing, although they can also be highly effective in germicidal applications.  Medium Pressure lamps are effective in germicidal applications and are typically used for air, water, and surface disinfection, while high pressure lamps are typically used to alter the properties of photopolymers in many UV curing processes.

Benefits of UV Light Curing

There are a multitude of benefits to using UV lights for curing, some of the most important would be efficiency, consistency and safety.

Efficiency

There is no other method that is quite as efficient at curing products as using UV light.  Depending on your operation, you could utilize specific UV light curing machines for your process or use more of a conveyor type of UV curing station to instantly treat numerous parts, without even touching them.  Imagine the time, money and labor you save by having an instant curing process occurring simply while your parts are being transported from one station to another such as quality inspection or shipping. The alternative methods such as drying or using solvents are less desirable due to several factors.  Force drying or air-drying products leaves them susceptible to inconsistencies with evaporation and possible contamination, and takes more time than an instant UV cure.  In manufacturing, time is money, and anytime you can improve your cycle time with a higher level of quality, it is evident which method is preferred.   UV light curing dramatically improves throughput and cycle times, with less costs than additional labor and purchasing chemicals which could be harmful to employees and the environment.

Consistency

Consistency is key to producing high quality products.   UV curing produces a consistent process with an even amount of UV exposure applied to parts and products, whereas employees applying a chemical spray for an outer coating can produce inconsistencies in the finished product.  Allowing parts to air dry also leaves room for an inconsistent finished surface due to evaporation.  As all quality minded OEM’s are aware, consistency increases the quality of products in all processes.

Safety and Health of Employees

While efficiency and consistency are top considerations for any production process, the safety and health of your workforce is also a top consideration.  With UV curing there is no emission of harmful pollutants and chemicals in the air, and no need to purchase or store hazardous materials and maintain material safety data sheets on such materials.  Using ultraviolet radiation is effective on photopolymers, and safe to the environment and your workforce.  With all these benefits, it is no wonder that OEMs, quality and production managers are realizing the value of ultraviolet radiation to enhance their production processes.  Cost efficient and consistent processes dramatically increase throughput and profitability.  Combined with health and safety practices UV curing is the most desirable of processes used to cure product surfaces.

LightSources Leads the Industry in UV Light Curing Lamps

LightSources and our European partner, LightTech, lead the industry with high quality UV lamps and custom designed solutions.  As an ISO registered lighting specialist, we understand the importance of high-quality product, delivered on time.  LightSources goes above and beyond any other lighting supplier with knowledgeable engineers ready to provide custom designs and prototypes with the right lamp for your process.  We can develop lighting solutions to be installed vertically or horizontally, while maintaining effectiveness.  Our lamps are proven to maintain effectiveness longer than other comparable types.

LightSources and our valued partner companies represent the leading high-tech lighting specialists and lamp designers in the industry today.  Our products are used in a multitude of industries and applications worldwide.  We offer OEM oriented and patent protected lighting solutions.  We invite you to contact us to learn more about our wide selection of UV light curing lamps.  

Lighting Specialist Provides Many Beneficial Uses of Light

Ultraviolet and fluorescent lamps provide a multitude of technologically advanced uses of light, with specialty lamp designers harnessing the power of UV radiation for many commercial and industrial purposes around the globe.  The LightSources Group is a leading specialty lamp manufacturer with in-depth knowledge of the many uses of light, providing effective and cost-efficient lamps for several applications.  Some of the most common uses of UV and fluorescent lighting include:

• Illumination – lighting for homes, offices, warehouses

• Signs – illuminating signs in any shape or size

• Backlighting applications – miniature fluorescent lighting is used in avionic display illumination and backlighting in computer and technological applications

• Phototherapy – UV lights provide health benefits to a wide range of illnesses

• Tanning – LightSources provides patented technology for maximum tanning effects

• UV Curing – UV curing solutions are used in many industries to improve quality and cost- efficient operations

• UVC Germicidal Applications – Ultraviolet energy is highly effective at eradicating bacteria and viruses from air, water and surfaces

Illumination with Specialty UV Lamps

Illumination is the obvious and most common of the many uses of light, with a wide variety of types and styles of ultraviolet and fluorescent lighting available.  Fluorescent light bulbs have a phosphor coating on the inside which converts the ultraviolet radiation into visible light.

LightSources offers specialty fluorescent lamps and lighting solutions in a wide array of standard lamp sizes with custom options available.  Our valued partner, LCD Lighting (LCDL), is a leading manufacturer of T2, T4, T5, T8 and T12 fluorescent lamps.  LCDL also provides CCFL sub-minis, HCFL-aperture and reflectors, compact fluorescent lamps and aquarium lighting solutions.

LCDL offers a wide range of standard sizes and custom sign designs for home or commercial use.

Phototherapy Uses of Light Provide Medicinal Benefits

UV lamps provide phototherapy to people that suffer from a wide range of medical ailments.  UV lamps are proven to improve skin conditions such as psoriasis, and improve mood disorders including depression and seasonal affective disorder.

Tanning

LightSources offers highly effective tanning solutions with patented and proprietary technology to provide greater tanning intensity with longer lasting effects.  Our low-pressure fluorescent, dual and triple-phosphor and high pressure facial tanning lamps deliver innovative solutions to tanning salons, providing greater satisfaction to clients.

We transform the many uses of UV light into the most effective tanning lamps available today with our cutting-edge tanning technology including: Multitone™, A-Power™, SolGlass® and Peak 2® technology with custom twist and swirl proprietary bases.

UV Curing

Ultraviolet radiation is used by OEMs and manufacturers worldwide to instantly dry paints, inks, coatings, and adhesives.  UV curing causes a chemical reaction on certain polymers that creates a strong, unbreakable bond or quickly dries outer surfaces.

UV curing is proven to be effective at curing and bonding, and more efficient and cost-saving than other methods such as air drying or chemical use.  Air drying can leave an inconsistent surface due to evaporation, and the use of chemicals can pose hazards for employees.  UV curing is used in many commercial and industrial processes around the globe, including screen printing, surface treating on various parts and components, and secondary applications in a variety of processes.

UVC Germicidal Lamps

Ultraviolet light delivered at short wavelengths provides very powerful disinfection properties that quickly eradicate viruses, bacteria, and microorganisms.  Germicidal applications are one of the many uses of light practiced worldwide for the disinfection of water, air, and surfaces.  UVC germicidal lamps are used in a wide variety of applications such as purifying the air in hospitals and doctor offices and disinfecting water in local municipalities’ wastewater treatment plants.

UVC germicidal water treatments are also used in the international shipping trade to treat the ballast water in ships, preventing the spread of dangerous and toxic marine organisms, and protecting the oceans of our planet.

UVC germicidal lamps are also beneficial in the food industry, disinfecting food purification systems in restaurants, grocery stores, and public areas.

The LightSources Group Develops Cutting-Edge Lighting Technology

The LightSources group is dedicated to research and development, providing cutting-edge lighting technology in the many uses of light available.  Our Amalgam lamps incorporate patented technology such as LongLife™, a specialty coating applied to all amalgam lamps to increase the UVC output up to three times what a standard lamp produces.

Our proprietary technology and patented products deliver high intensity with longer-lasting high performance.  When it comes to the numerous beneficial uses of light, no one knows this technology better than LightSources.  We provide custom solutions from experienced and skilled design engineers that have in-depth knowledge of all types of lamps and lighting solutions.

The LightSources Group and our valued partner companies – LightTech, LCD Lighting, Voltarc and Cerlux – represent the leading manufacturers and high-tech lamps designers in the lighting industry today.  Contact us to learn more about our superior lighting solutions with custom designed lamp products for virtually any application.