The State of UV LED Today Michael Beck Phoseon Technology

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1 The State of UV LED Today Michael Beck Phoseon Technology Presented to the ASC Convention April 4, 2017

2 Phoseon Technology Company 100% LED focused Over 250 Patents LED Pioneer since 2002 Over 65,000 units shipped HQ in Portland, Oregon USA Supply chain control Coverage Europe Middle East Americas Africa World-wide support Asia Pacific ISO 9001: 2008 Certified Page 2

3 Initial Market: UV LED Curing UV ADHESIVES UV COATINGS UV INKS Displays Electronics Speakers Medical Industrial Cables Wood Displays Digital Inkjet Flexographic Screen Offset Enabling New Capabilities & Processes Worldwide Page 3

4 UV LED Adhesive Applications UV LED curing is ideal for adhesive applications providing accurate, safe, and high quality adhesion Labels Plastic & Glass Food Beverage Pharmaceutical Medical Syringes Catheters Endoscopes Hearing Aids Industrial Electronics Fixtures Tile Concrete Consistent, reliable, repeatable UV output Page 4

5 Conventional UV vs. UV LED Page 5

6 Industrial UV Energy Sources Voltage Arc/Electrode (1940s) Microwave (1970s) UV LED (2000s) Page 6

7 LED Basics A solid-state semiconductor device that produces light when an electrical current is allowed to flow from the positive (p-type or anode) side of the circuit to the negative (n-type or cathode) side This is called the p-n junction LED output has increased over time, but it s more of the Array, Optics, and Thermal management design that has allowed an increase in UV Irradiance output Page 7

8 UV LED vs. Conventional Lamps UV LED Mercury Lamp Lifetime (on-time) > 20,000 hours 500-2,000 hour bulb life Environmental Mercury Free Ozone Free Mercury Waste Ozone Generation Input Power Small (< half) Large Maintenance Minimal Bulb replacement, reflector cleaning/replacement On / Off Instant Minutes Heat 60 C 350 C Page 8

9 Wavelength Comparison UV LED lamps available at 365, 385, 395 or 405nm wavelengths. Materials must optimized for narrow wavelength. Output power can exceed 1kW of pure UV-A energy. Extremely high power in narrow range Page 9

10 Phoseon LED Lifetime (On-Time) UV Intensity 100% 90% 80% 70% Conventional Lamps: Replaced every 2,500 hours LED 10K 20K 30K 40K 50K 60K Hours Phoseon has over 50 units on longterm life test at any single time. Testing includes various duty cycles, high-temperature, air-flow reduction, and other stress test parameters. > 60,000 hours An example of test data Over 2 Million hours of SLM lifetime testing Page 10

11 UV LED Value Proposition More consistent UV output and stable semi-conductor process. Higher quality curing and higher-yield production. Instant-on/off and ultra-long lifetimes More productivity, higher utilization. Elimination of consumables; replacement bulbs, reflectors, magnetrons, etc. Lower heat-load on the curing area (no IR) Heat sensitive materials. Safer work environment. Energy requirements reduced (50-90% reduction in energy required) Reduced operating costs. Reduced or eliminated infrastructure for exhaust, ozone removal, etc. Environmental advantages No mercury disposal issues. No ozone generation. Dramatically lower carbon footprint. Customer acceptance of UV LED has pulled suppliers and formulators Page 11

12 Challenges of UV LED LED lamps are divergent sources which can impact working distance. Peak irradiance decreases with distance. Optics/reflectors can mitigate this in some situations. Light guides are generally very inefficient with UV LED. Chemistry of adhesives may have to be optimized. Photoinitiators are limited to UV-A types Oxygen inhibition issues can require reformulation. A large number of recent new suppliers have entered the marketplace. Low cost offerings can compromise reliability, lifetime, and consistency. Specifications/standards still being developed. IP related issues have yet to emerge. Measurement devices (radiometers) must be designed for UV LED. In spite of the challenges, UV LED systems have proven to be an extremely effective solution for a growing number of applications. Page 12

13 Types of UV LED Lamps Page 13

14 Thermal Management is Critical This is not radiated IR energy but energy created by electrical inefficiencies. Approximately 35% of input power is converted to useable UV output. Approximately 65% of input power is converted to unwanted heat. Cannot exceed maximum LED junction temperature and maintain lifetime. Cooling is designed to optimize the efficiency of the LEDs. Cooling can be air or water. 30% 70% Page 14

15 UV LED Sources Air Cooled Internal Heat Sink Cooling Fins DC Power, Control, Diagnostics Cooling Fans W/cm 2 Emitting Window and Semiconductor Light Matrix (SLM) of UV LEDs 385, 395, & W/cm 2 Page 15

16 UV LED Sources Water Cooled Internal Heat Sink Water Manifold Water Cooling Tubes Emitting Window and Semiconductor Light Matrix (SLM) of UV LEDs DC Power, Control, Diagnostics W/cm 2 385, 395, & W/cm 2 Page 16

17 Air-Cooled vs. Water-Cooled UV LED Water-cooled UV LED systems Are capable of higher power. Are usually smaller and more compact. Require a recirculating chiller or heat exchange system. Water must be clean and treated with additives to avoid corrosion. Condensation is a concern if water temperatures below the dew point. Systems spec d for 30C better than 15C in resisting condensation. Air-cooled UV LED systems More cost effective since a chiller/plumbing/water maintenance not required. Slightly less efficient than water cooled systems. The power of some air-cooled systems now equals or exceeds water cooled systems of 2-3 years ago. Air-cooled systems are generally larger to due fan and heat-sink configurations. Page 17

18 The Current State of UV LED Page 18

19 The Current State of UV LED Technology Performance Continues to Improve Irradiance (Watts/cm 2 ) and energy density (Joules/cm 2 ) increasing. Available form factors expanding. Reliability, efficiency, and life of lamps increasing. Prices decreasing UVA is the most prevalent UV LED output. UVB and UVC Sources still not commercially viable for most applications. Growing number of UV LED lamp suppliers. Applications are expanding rapidly. UV LED curing is commercially used for inks, adhesives, and coatings. New applications are being explored daily. Applications are switching over quicker than predicted in many segments. Formulation development tends to be end-user driven New raw materials are being introduced to facilitate reformulation. Page 19

20 Choosing a LED Curing Supplier LED Capability Percentage of resources dedicated to LED? Percentage of revenue from LED? Demo units available for testing? Bare or packaged diodes for array customization? Intellectual Property Number of LED patents? Enable end-users freedom to operate? Worldwide coverage? Reliability Utilize Highly Accelerated Life Tests (HALT)? Utilize semiconductor mfg and burn-in process? Long-term life testing > 60,000 hours. ISO certified? UL Qualified products? Service Worldwide Sales & Technical support? Worldwide LED understanding? Root cause analysis & reporting? The skill-sets and capabilities required for UV LED include electronics, semiconductors, optics, thermal management, packaging, mechanical and reliability engineering Page 20

21 Conclusions UV LED lamps are replacing conventional Hg-based UV lamps every day. The number of applications continues to grow. The challenges associated with formulation have been resolved in most inks, many adhesives and some coatings. More work to be done but initial acceptance indicates that most obstacles are business related, not technical. The costs of UV LED lamps have reached acceptance for many applications. Initial investment approaching or at parity with high quality Hg systems. Compelling value proposition. Superior cost of ownership. Customer acceptance is very high. Once the transition is made, there is no reversion to conventional technology. The customer should evaluate any potential supplier thoroughly and confirm (or separate) the claims from the data. Page 21

22 Thank You! Questions? Michael Beck Director of Sales, Americas Phoseon Technology Page 22

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