Surface cleaning and surface modification using UV light

Short-wave ultraviolet (UV) light can be used to clean or modify surfaces so that coating, adhesion, or bonding processes can be carried out effectively. Glass, plastic, metal, ceramic, rubber and other materials can be treated this way. For this application, mainly low-pressure mercury lamps with high light output are used. Corresponding lamps are integrated into a variety of lighting systems from SenLights.
A major application area is the cleaning of glass in LCD manufacturing.

The technology

Introduction

The sun emits UV light. The ozone in our atmosphere is produced by a chemical reaction triggered by UV light. The same chemical reaction can be used in UV light systems to treat surfaces.

Sunlight - ozone formation

Actual surface cleaning occurs through oxidation and cleavage of organic surface contaminants. Mainly carbon dioxide and water are formed. The oxygen radicals used for this are produced by splitting ozone molecules, which themselves are formed from oxygen molecules by irradiation with UV light. Both the formation of ozone and its decomposition are triggered by the high-energy UV irradiation of low-pressure mercury vapor lamps. These lamps are therefore ideally suited for such surface-cleaning applications.

Ozone produced by UV light

  • The 185 nm UV line splits oxygen molecules and leads to the production of ozone O3. The 245 nm UV line decomposes ozone, producing highly reactive free oxygen radicals O (activated oxygen).
  • Radicals such as OH, COO, CO and COOH are formed and increase the hydrophilic properties of the treated surface.
  • Organic molecules are broken down by UV light and oxidized by the oxygen radicals. CO2 and H2O are formed and desorb from the surface.
  • The surface is freed from organic contamination and becomes more hydrophilic.

Cleaning effects

Fundamentally, two different effects caused by UV light on a surface are distinguished: surface cleaning and surface modification. The reaction mechanisms differ, but both processes have a positive effect on adhesion forces and the bonding properties of the treated surface. UV light and plasma etching produce a considerably higher cleaning effect on surfaces than conventional wet cleaning. Organic substances, and especially fats, can be reliably and thoroughly removed. However, this applies only to thin layers. Therefore the most effective cleaning is a combination of conventional wet cleaning followed by photochemical cleaning with UV treatment. A post-rinse with ultra-pure water can be added if necessary to remove any particles generated during photochemical cleaning. This is the current state of cleaning technology.

Surface modification

Compared with plasma treatment, UV surface processing offers the advantage of easier handling. Moreover, UV irradiation can be applied to almost any geometry by arranging lamps or designing lamp shapes. The method can therefore be used, for example, on cast parts. Plastic parts can also be treated effectively because of the low process temperatures. The treatment success naturally depends on the material and its properties. Under clean conditions, the cleaning effect can last for weeks.

Adhesion effects

After treatment with UV light, the surface is cleaned or modified and adhesion forces are increased. Wettability of the surface changes and this property is used to measure the cleaning effect. Several methods are applied:

Contact angle of a water droplet.

A good method to determine the hydrophilic nature of a surface is to measure the contact angle of a deposited water droplet. As wettability increases, the angle between the water droplet and the surface becomes smaller. The method is very accurate and can also be automated.

Contact angle

Wettability reagent.

Another method uses a special wetting agent whose spreading on the surface is observed. In this case it is necessary to wet reference surfaces and compare the spreading of the agent on the reference surface with its spreading on the surface to be tested. The accuracy of the test method depends on the experience of the tester.

Wetting test

Use of wetting grids.

In this method, an acrylic lacquer is applied to the surface and scored into a grid. A cellophane film is applied to the lacquer and then peeled off. Depending on the adhesion, more or fewer lacquer squares come off the surface. The number of detached squares is counted.

Wetting grid
Applications

The development of ever newer high-tech products increasingly requires precise definition of surface properties. Short-wave UV light is capable of producing reproducible surface properties through cleaning and modification effects. This method is nowadays an indispensable option. In this way, production yields can be increased. This applies to many different applications from optoelectronic components to semiconductor and LCD applications, as well as surface preparation for bonding or use in medical technology and environmental technology.

The method can be applied as dry cleaning in normal atmosphere, shows very high effectiveness, is versatile and hardly damages the product.

Increase of adhesion forces.

Surface improvement can be applied to different materials such as plastics, metals and inorganic materials. Some applications are, for example, aquarium sealing, bonding of plastic or rubber parts, application of aluminum foils in capacitor manufacture, assembly of magnetic heads, semiconductor lead frames, ...

Improvement of bonding properties.

Optimal fixation of lubricants, protective lens coatings, backlights for liquid crystal displays, etc.

Improvement of coatings.

This effect can be used, for example, in coating car body parts or coating superconducting linear motor coils.

Cleaning effects.

Cleaning of glass or ceramic products as well as metal surfaces is a standard application of UV irradiation. It is used in LCD manufacturing and plasma display production, in the cleaning of lithographic masks, in the production of quartz oscillators, cleaning optical lenses, prisms, mirrors, piezoelectric components and many other parts.