How LED Manufacturers Can Improve Production Throughput
The LED lighting revolution is in full swing. Technology has improved over the last few years, and the numbers speak for themselves. Users are switching from incandescent bulbs to LEDs in their homes and at work. Auto manufacturers are following the trend, too. Once reserved for luxury cars, LED headlights are finding their way into lower-end models.
This increased demand has made the marketplace extremely competitive. That’s great news for consumers, but presents a challenge for your manufacturing plant. The movement toward constantly decreasing device cost has driven the need for more efficient production processes. So, where do you start?
Decreasing Cost by Increasing Efficiency
Improving efficiency in production throughput means spending less time manufacturing. To achieve this, one area to focus on is processing. How long does it take to turn raw materials into finished goods? Are there better, more efficient ways? Your discussion on where improvement is possible should begin with the choice of solutions required to process raw materials into an LED component or sub-assembly.
At Henkel, we’ve identified three major areas where processing can be improved and have developed a number of fast-cure solutions, all of which deliver a beneficial impact on solving the issues that impact throughput.
Challenge: Slow curing on lens assembly
Solution: Loctite 3972
Using a light cure, one-part acrylic will save you tons of time during lens assembly. Its cure time can be measured in seconds, not minutes or hours like conventional silicones and epoxies. It also incorporates easily into automated production lines, and provides reliable bonding to glass, plastic and metal.
Challenge: Manual cut gasket repair/replacement
Solution: Loctite 5039
Switching to cure-in-place gasketing eliminates the time and manual labor required to replace cut gaskets on assemblies. Cure times for this light cure silicone are less than one minute for a bond line in a lens assembly or housing.
Challenge: Boosting gel time
Solution: Loctite 5611F for potting
This two-part silicone has an exceptionally fast gel time, as well as a low viscosity for optimal flow in parts.
With these Loctite solutions, it’s possible for manufacturers to eliminate the racking process, and achieve faster throughput with minimal equipment changes. The ability to ramp up hourly/daily production in this cost-effective manner may postpone (or even eliminate) the need to increase plant capacity, and the investment required to upgrade physical assets.