UltraLED Curing System

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Systematic Automation Inc. has developed the UltraLED System for curing your LED inks, coating and adhesives. The system (18 watts/cm^2 irradiance) provides ample power while being compact. UltraLED emitters can last +20,000 hours, allowing your investment to pay for itself.

UV LED is a long term solution that is cost effective. You will save significantly on energy and disposal costs that you would normally incur from conventional mercury vapor lamps. The emitters from the system turn on instantly, without warmup. The UltraLED is liquid cooled, providing you with more curing power and less noise compared to standard fan cooled UV LED systems.

Universal mounting of the UV LED irradiator head allows for easy integration onto existing equipment to replace conventional UV or hot air drying systems. We provide application engineering support and manufacturing support for any custom brackets or guarding required for your installation.

Click here for more information on typical UV LED applications.

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Engineering Features

  • Liquid cooled
  • Consistent uniform UV light
  • Compact and easily integrated
  • Modular design
  • Ozone free
  • Lower curing temperature protects heat sensitive products
  • Instant on/off control eliminates warm-up time associated with mercury vapor lamps which saves power
  • Uses significantly less energy compared to arc lamps

Advantages of LED

  • LEDs last 20,000+ hours vs. 1,000 Conventional UV
  • Compact and easily integrated
  • Eliminates UV lamp replacement costs
  • No downtime to change lamps
  • Instant peak power
  • Lamp degradation from on/off toggling eliminated
  • LED systems do not contain mercury, which has a disposal cost
  • Does not require a ventilation system (no ozone produced)
  • Contact us to determine if LED curing is the proper solution for your product

UV curing has been incorporated into industrial applications for over 30 years. UV LED curing is becoming the benchmark for UV curing and is providing a more long term cost effective, cooler, ozone free and energy saving solution. Our UltraLED systems are modular and can be integrated into existing equipment. If you don’t have existing equipment, we will manufacture you a conveyor or UV spin cure (for cylindrical substrates) with UltraLED integration. We offer UV LED solutions for screen printers, digital printers and more.

A UltraLED curing head generally comes as an array of LEDs. The number of LEDs in an array can be configured in any shape or size. The light energy source coming off the semi-conductor is a diffused light source. Diffused light sources are materials or surfaces which scatter light in every direction. The intensity or luminosity of the light from a diffused source appears the same regardless of the viewing angle. Due to this physical property of LEDs, and the fact that there is virtually no heat directed at the printed material, the LED head may be as close to the printed material as possible. To cure properly, LED inks must be formulated to the narrow wavelength given off by the LED.

Although there is essentially no heat projected on to the print surface, heat is a by-product of the quantum physical reaction at the semi-conductor junction. The semi-conductor junction is that part in a diode where electrons (negative side) of one semi-conductor layer react with protons (positive side) from another semi-conductor layer. High ambient temperatures shorten the life of an LED. High temperatures cause more current to pass through the junction which causes the LED to overheat.

UV LED used for curing is generally packaged as an array. UV LED arrays are as varied as there are manufacturers. Similar arrays from different manufacturers may not cure the same ink exactly the same. Several diodes are connected together to form the head. The arrays or heads may be any shape but the most common is rectangular.

Most LEDs also have some encapsulation not only to protect the semi-conductor chip but also to direct the light efficiently. The encapsulant or case may be placed over the whole array or may be on individual chips of the array. Encapsulant material is generally epoxy. Inks formulated for UV LED are optimized to have the photo initiators absorb UV energy at the specific wavelength emitted by the UV LED array. The digital printing industry was the first to adopt the use of UV LEDs. Curing with UV LEDs is growing in popularity and spreading to other printing technologies.

Industries Served

  • Adhesives
  • Medical devices
  • Roll-to-roll
  • Screen printing
  • In-line coating
  • Digital printing
  • Offset printing
  • Paint/ink/lacquers
  • Industrial applications
  • Your application