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What is UV?

UV is an abbreviation of Ultraviolet rays. As invisible rays, it is Hertzian waves in a band outside the purple visible rays, and the wavelengths are normally divided into following several branch bands with different characters.
A. Vacuum UV, with wavelengh 10~200nm
B. UV-C, with wavelengh 200~290nm
C. UV-B, with wavelengh 290~320nm
D. UV-A, with wavelengh 320~400nm
E. Visible light, with Wavelengh 400~760nm
UV is used in industrial processing, and UV-A is more frequently used than any of others.

Theory of UV Solidification

UV solidification makes use of the phototonus of photosensitive materials. Some molecules of the photosensitive materials get energy from UV, and step into the excited state, subsequently decompose themselves into disengaged elements or ions. The disengaged elements or ions promote the unsaturated organic compounds to complete polymerization and coalesce etc chemical reactions. And the process of solidification is completed when the chemical reactions are over and the photosensitive materials turn into solid completely.

Disposal methods to the infrared radiation of UV

Sixty percents of the total power of the Ultraviolet High Pressure Mercury Lamp are converted to infrared radiation, and the surface temperature of the lamps maybe rise up to 700~800 o C. To avoid excessive temperature rising, people pay much attention to adopting more efficient lamps and multi-lamps systems. So multi-measures is always taken to cool the lamps, reflecting cups and supporting materials. Since high temperature is in favor of solidifying dope, when UV is used to solidify dope, the temperature should be well controlled so that ones could get nice solidification with a suitable surface temperature. There are three widely used measures, one is wind cooling, which is most frequently used with a little cost; One is water cooling equipped with water jacket covering the lamps, the effect is nice, but the cost is much larger; Another is adding optic discs and keeping the solidification materials free of infrared radiation, it is suitable to the shape easy-changing product.

The Function of Reflecting Cups

With reflecting cups, it is easy to focus the energy of UV lamps to the surface of the product. The effect of the reflecting cups will affect the quality of products directly. The reflecting cups of Blue Sky Special Lamps Company, are equipped with imported aluminum alloy flat-plane reflecting sheets, and the reflecting effect is more nice.

The factors to UV deep solidification:

The UV photosensitive dope is initiated by UV radiation, and generates disengaged elements or ions. The disengaged elements or ions react with the unsaturated organic compounds and complete polymerization and coalesce etc chemical reactions. And the whole process of solidification is completed when the chemical reactions are over and the photosensitive materials turn into solid completely. The factors affecting the deep solidification are show below:

The affect of UV energy
The primary condition of UV deep solidification, is that the molecules of the UV photosensitive dope need get enough energy to step into excited state and to decompose themselves into disengaged elements or ions. The disengaged elements or ions promote the unsaturated organic compounds to complete polymerization and coalesce etc chemical reactions, and the solidification is completed gotten.
If the energy supplied to the UV photosensitive dope is excessive or deficient, below questions will occur:
a) When the energy necessary for complete solidification is known, it is normal that the supplied energy is slightly and reasonably more than necessary energy.
b) When the energy necessary for complete solidification is unknown, if one blindly supplies excessive energy, the energy will be wasted and bad feedbacks to over-solidification will occur.
c) If the power of UV is deficient, the energy of UV must be suitable to avoid incomplete solidification.

The affect of the thickness of UV dope
The thickness of UV dope takes a pivotal affect on the effect of UV solidification. If the dope thickness is larger than normal value, the solidification time will be longer with a same power lamp. On one side it will lower the solidification efficiency, on the other side it will result in the surface temperature of supporting materials higher and the supporting materials reshaped. If the dope thickness is less than normal value, it will result in bad surface appearance of products. Additionally, the color of dope, temperature, solidification speed and surface of supporting materials will affect the adjustment of dope thickness.

The affect of distance
If the distance between the surface of product and the UV lamp as well as the reflecting cup is among 7cm and 8cm, the solidification effect will be nice. But the distance is usually among 10cm and 15cm in accordance with the supporting materials. When the distance is less than normal value, the supporting material will be reshaped due to the high surface temperature of UV lamp. When the distance is larger than normal value, the surface of supporting materials is difficult to dry due to less UV energy. Thus, the distance should be adjusted in accordance with supporting materials, dope and the power of UV lamp.

The affect of solidification speed
The solidification speed should be adjusted in accordance with supporting materials, dope and distance etc. If the solidification speed is higher than normal speed, the UV dope on supporting materials will be adhesive or be dry on surface but adhesive inside. If the solidification is lower, the surface of supporting materials will be aged.

In a word, one should practise in actual processing and sum up experience frequently to well master the skill.

Failure and Steps

  Failure Reason Step
  UV dope solidification incomplete

Low power density of lamp
Lacking photosensitive materials
Low temperature or short solidification time Far distance

Change a large power lamp
Change dope Increase solidification time
Higher temperature and adjust distance

  Dark lamp or twinkle lamp
High voltage or unsuitable transformer
Measure voltage and related parameters
  Lamp reshaped
Bad cooling and high surface temperature
Increase power of cooling
  Lamp bombed

High voltage
Dirty on lamp surface
False joint
Circuit short
Mismatched power supply voltage

Change lamp
Caution dirty
Repair
Repair
Select suitable voltage

  High temperature of transformer

High voltage more than 10%
Bad ventilation

Decrease voltage
Increase ventilation

  Bombed lamp neck High voltage or false joint Change lamp
  Melted lamp head Bad cooling and high temperature Increase power of cooling
  High lamp intensity

Unsuitable transformer
Strong circuit intensity

Measure (change)
Change ballast

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Booking index for UV lamps

 Wire 1:
 Length: L1
 Diameter: D1
 Vendor:
 Lamp model:
 Device model:
 Wire 2:
 Length: L2
 Diameter: D2

 L= B=
potter insulator face wire
flank wire
metal head screw
straight
 A= C=
 D= E=
 L1/L2= F=

 lamp power=
 start voltage=
 service voltage=
 current intensity=
 Power density=
wavelength tube parameter
 Hg/UVC 254nm 
 Fe/UVA 365nm 
 Ga/ViS 420nm 
 other/UVC 250nm
 standard
 free oxygen
 sum

remark  Used: Country company life effect:
 others:

 Customer:
 Address:
 linkman: Section:
 Tel/Fax:

Purchase order:
Lamp model:
quantity:
date:

     

 


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