Fiber coating UV LED for Fiber drawing coloring high speed and high quality
Traditional UV curing employs mercury arc lamps to create ultraviolet light, which causes inks, adhesives, and coatings specific to the process to undergo a chemical reaction (called polymerization) that converts them from a liquid to a solid when exposed to it. Ideally, they become securely stuck to the substrate onto which they were printed - a.k.a., they are securely cured, with adequate depth of cure (they aren't tacky or sticky).
And though mercury arc lamps are widely deployed as UV curing solutions - they work well, and have been around a long time, so people are familiar with how they function - they have their downsides: they produce ozone and require exhaust systems to maintain air quality; they use a lot of energy and create a lot of heat; and they involve the use of mercury, which has a long-term environmental impact and is facing ever-increasing monitoring due to this fact, like the European Union’s recent Restriction on Hazardous Substances II (RoHS II) regulation, which bans the use of heavy metals including lead, mercury, and cadmium.
LED UV curing is a relatively new process that many printers and converters are still learning about - but, in short, it provides solutions to the issues most commonly encountered with heat-set drying and traditional UV curing, from those of quality to those of environmental impact.
Fiber coating curing is a highly skilled process. In the fiber drawing tower, it is produced at a speed of 2km per minute. The UV curing process determines the quality of the fiber. Traditional curing methods consume a lot of electricity, generate a lot of heat, and have high maintenance costs. UV LED technology makes up for the traditional UV-cured shortboard, which is a new, energy-saving and efficient technology.
For every 1 centimeter of fiber produced, the LED UV lamp and the extraction system use approximately 0.5-0.7 degrees of power. We produced about 240 million core kilometers of fiber in 2018 in China, and the total power consumption will exceed 160 million kWh.
Compare with conventional UV lamp
1. For every 1 centimeter of fiber produced, the LED UV lamp and the extraction system use approximately 0.5-0.7 degrees of power.
2. We produced about 240 million core kilometers of fiber in 2018 in China, and the total power consumption will exceed 160 million kWh.
3. UV-LEDs are five times more efficient than mercury lamps.
4. If UVLED is applied for optical fiber production in 2018, it can save RMB256 million(It's the visible cost).
5. Invisible cost : Extracting the heat generated by the drawing tower area and maintaining the constant temperature of the cleanroom( 23-26°C & 50% RH); the high curing efficiency of UVLED peak intensity can increase the drawing capacity; but the heat generated by mercury lamp will cool the exhaust system, and the cost of consumables in the mercury lamp use process;
Technical advantages of UV-LED:
UV-LEDs are five times more efficient than mercury lamps.
If UVLED is applied for optical fiber production in 2018, it can save RMB256 million. (It's the visible cost)
Invisible cost : Extracting the heat generated by the drawing tower area and maintaining the constant temperature of the cleanroom( 23-26°C & 50% RH);the high curing efficiency of UVLED peak intensity can increase the drawing capacity, but the heat generated by mercury lamp will cool the exhaust system, and the cost of consumables in the mercury lamp use process;
UV LED Optical Fiber Curing Light Parameter:
| Specification | Valid emitting area(mm ) | Illuminate distance(mm ) | Wavelength(nm ) | Luminous intensity(mW/cm2 ) | uniformity | Luminous half Angle | Cooling method |
| UVLED Spot Light Source | ＞φ10 | 350 | 365 | ＞400 | ＞90% | 1.7° | Nature convection |
| UVLED Area Light Source | 280x190 | 350 | ＞480 | ＞80% | 1.7° | Water cooling |
Technical advantages of UV-LED
► Intelligent design, self-test, abnormal alarm function. High-temperature warning, real-time monitoring of light intensity, automatic adjustment.
► Drive independent research and development design, currently used in large quantities, stable and reliable performance;
► Precision optical design for optimal illumination output;
► Precision heat dissipation design ensures optimal heat dissipation of LED modules;
► In India, Thailand, Singapore and the European Union, we have a 24-hour after-sales service team.
Optical modeling simulation
Application: Curved phone cover exposure
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365nm Wavelength UV Adhesive Curing Systems Optimal Illumination Output Images
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