UV Curing Technology
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About UV Curing Technology |
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Request for Quote About Electrode UV Curing Lamps
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Introduction Ultraviolet reactive inks and coatings require a high intensity source of ultraviolet light to initiate a chemical reaction. This reaction cures the ink or coating almost instantaneously. Ultraviolet light forms a small part of the electromagnetic spectrum, which ranges from radio waves at the long-wave end, to x-rays and gamma rays at the short-wave end. The chart below shows how ultraviolet wavelengths fit into the electromagnetic spectrum.
The ultraviolet wavelengths most suitable for curing inks lie between 200 and 400 nanometers. There are several types of lamps suitable for generating these wavelengths. The most common are high-pressure mercury-arc lamps, microwave-powered mercury lamps, and medium-pressure mercury-arc lamps. The high-pressure mercury-arc lamp is generally constructed as a capillary type tube and requires a water jacket to maintain correct running temperatures. These lamps are limited to short lengths only, and lamp life is usually less than 1000 hours. In the microwave-powered mercury lamp, an arc is established by the generation of microwaves. This requires fairly large and expensive "magnetrons," which are placed at each end of the lamp. Again, these lamps can be produced in only short lengths. By far, the most widely used is the medium-pressure mercury-arc lamp (an MPMA Lamp). This can be air or water-cooled, and can be manufactured in a wide range of lengths. Single lamps two meters (six feet) long are not uncommon, and the working life of MPMA lamps can be expected to be well over 1000 hours. Typical MPMA Lamp Construction
The body of the lamp is made from transparent vitreous-silica tube of various diameters and wall thicknesses. This material, referred to as quartz, is expensive, but has important properties vital to the efficient operation of an ultraviolet system. Quartz has 90% transparency to ultraviolet light, whereas normal glass filters out all ultraviolet except the longer, weaker wavelengths. The surface temperature of an ultraviolet lamp under normal operating conditions is between 600° C (1,100° F) and 800° C (1,500° F). Quartz is able to withstand these temperatures as it has a very low thermal expansion characteristic and high melting temperature. The electrodes, from which the high voltage arc is sustained, are made from a tungsten rod over-wound with tungsten wire. Tungsten is necessary to withstand internal arc temperatures over 3,000°C (5,400° F). Electrodes must be designed carefully to ensure efficient, reliable operation and long lamp life. The parameters affecting this design are extremely complex. Because of the high running temperatures and the low expansion characteristic of the quartz, the correct selection of a suitable material to connect the electrode inside the envelope to the power supply on the outside of the envelope, is very important. The material used is molybdenum foil, which has a low coefficient of expansion and is capable of carrying the high voltage required to sustain a stable arc. Additional electrical connections are made using high-temperature wire. Electrical insulation at the end of the lamp can be achieved by the use of a ceramic end cap. Electrical Requirements For MPMA Lamps Due to the electrical nature of a medium-pressure mercury-arc lamp, line voltage alone is usually insufficient to operate the lamp. Therefore a step-up transformer is used. These transformers have to be correctly matched to the electrical demands of each lamp size and type. Lamp control can be performed by the use of either an inductive, or a capacitive system. With an inductive system, the lamp is connected directly to the output of the transformer. When any fluctuation of the input voltage occurs, the output of the transformer also varies proportionately. This then alters the output of the lamp. With a drop in input voltage the lamp output will drop proportionately. The capacitive system overcomes this problem by the use of capacitors connected in series with the lamp. This has the effect of maintaining a constant output to the lamp even when input voltage varies. This is known as a constant-wattage system and is, by nature of its design, the most efficient. Primarc Lamp Control Systems are designed to run as constant wattage capacitive systems. The diagram shows the electrical circuit required to control the running of such a lamp. Typical Constant Wattage Circuit
To ensure that the highest efficiency is obtained from Primarc lamps, the transformers and the control circuitry are designed and manufactured in-house to very exacting standards. Spectral Output Of An MPMA Lamp The achievement of the precise wavelengths of ultraviolet light suitable for curing ultraviolet inks and coatings is very important if a system is to be highly efficient. MPMA lamps emit not only ultraviolet light, but also visible light, and wavelengths in the infrared spectrum. In fact, all lamps emit approximately 20% ultraviolet light, 60% infrared light and 20% visible light. It is therefore important that when selecting a lamp, output in the ultraviolet spectrum should be closely examined. The ultraviolet spectral output is sometimes expressed graphically, showing the proportional output at the important ultraviolet wavelengths. A graph of a typical Primarc MPMA lamp is shown below. Typical MPMA Lamp Spectral Output
Lamp Life Unlike ordinary household light bulbs, medium-pressure mercury arc lamps do not normally fail suddenly. Rather, efficiency declines relatively slowly, until insufficient UV light is being emitted for the lamp to cure effectively. This decline is caused primarily by the deterioration in UV transparency of the quartz jacket, and depends on a number of factors including lamp cooling efficiency, power rating, current rating of the electrodes, electrode cooling efficiency, contamination of the lamp's external surface (dust etc.), and switching frequency. When used correctly, Primarc UV curing lamps will provide 1000 hours of useful life. All Primarc lamps are warranted against manufacturing defects.
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