Optical diffuser for improving photon capture to enhance photochemical reactions

Abstract

Optical diffusers and methods for manufacturing the same are described herein. In some embodiments, the method for manufacturing an optical diffuser may include forming a lenslet on glass or plastic to remove sharp scattering surfaces to form an optical diffuser, and connecting a container to the optical diffuser, the container being configured to hold a chemical substance, and the lenslet transmitting more than a certain percentage of light to the optical diffuser, and the percentage of light being more than 80%.

Description

Technical Field

[0001] One or more aspects of the present disclosure relate to the construction and use of optical diffusers for enabling the performance of chemical reactions using light, causing and / or catalyzing chemical reactions commonly referred to as “photochemical reactions”. More specifically, without limitation, one or more aspects of the present disclosure enable an optical diffuser that improves photon supplementation for the improvement of photochemical reactions.

Background Art

[0002] Light diffuser plates are common in many applications, from household appliances and area lighting to commercial, industrial, and office uses, and are most commonly found in lighting applications to diffuse and / or soften illumination. Optical diffusers are also light diffuser plates, but use more engineering techniques to define how light is diffused in a controlled (engineered) manner. Optical diffusers are also referred to as “engineered” diffusers, and the diffusion is carried out in a very controlled manner to create a distinct pattern with a repeatable and precisely predictable light distribution. Optical diffusers can be adjusted for the application, but in more common non-optical diffusers, control over the light distribution is minimal. Engineered optical diffusers have not been used in photochemical reaction vessels heretofore. FIG. 2A shows an example of a prior art diffuser that utilizes a non-optical diffuser transmittance in the approximate 50% transmittance range, i.e., approximately 50% of the light passes through the diffuser.

[0003] Typically, the vessels or windows used in photochemical reactions are made of polished glass, but may also be polished sapphire, plastic, or other transparent materials. The type of glass may also be fused silica, borosilicate, soda-lime glass, fused quartz, aluminosilicate, etc. See FIG. 1.

[0004] Known diffusers are available for photochemical reactions, generally allowing a transmittance of about 50% or less and being difficult to clean.

[0005] At least due to the limitations mentioned above, an optical diffuser is required to improve photon capture in order to enhance photochemical reactions. [Overview of the Initiative]

[0006] One or more aspects described herein relate to optical diffusers for improving photon capture in order to enhance photochemical reactions.

[0007] At least one aspect of the present invention uses a transparent container or window, wherein the inner and / or outer surfaces of the container and / or window are composed of an engineered optical diffuser (on the inner and / or outer surfaces of the diffuser with respect to the inner or outer surface of the container to which the diffuser is connected). As used herein, transparent means that light passes through so that an object behind the diffuser is clearly visible. The purpose of this diffuser(s) is as follows: • The light used to trigger or catalyze chemical reactions is homogenized, supporting more uniform and controlled emission of chemicals. • The signal is homogenized, thus avoiding hotspots. When more photons are concentrated in a small area than the concentration of a chemical that requires 100% reaction, a hotspot can damage the chemical being exposed to the light and / or waste photons. • When the light source is a laser, the laser tends to concentrate too much light into a narrow area (see "hot spot" above). Optical diffusers optimize the photoreaction by ensuring controlled, "strategic" diffusion of the laser light. Optical diffusers are designed to optimize the cone angle (full width at half maximum, "FWHM"), so the desired cone angle can be engineered to maximize the reaction efficiency. • Minimize the loss of efficiency by minimizing shadowing, which can occur when light passes directly through a transparent container and / or window(s) without proper diffusion. Shadowing occurs when the chemical itself absorbs photons and / or prevents photons from penetrating deeper, thus preventing the chemical deep within the chamber from reacting as quickly and efficiently as it would with a diffuser. [Brief explanation of the drawing]

[0008] The above and other aspects, features, and advantages of the present invention will become clearer from the following more specific description, which is presented in conjunction with the following drawings.

[0009] [Figure 1] Figure 1 shows a photoreactive chemical substance in a glass container exposed to a light source according to the conventional technology. [Figure 2] Figure 2A shows a non-optical diffuser with approximately 50% light transmittance compared to an engineered optical diffuser with at least 80% transmittance. Figure 2B shows an optical diffuser connected to a container according to an embodiment of the subject. [Figure 3] Figure 3 shows a method for manufacturing an optical diffuser according to one or more embodiments of the present invention. [Modes for carrying out the invention]

[0010] An optical diffuser for improving photon capture to enhance photochemical reactions and a method for manufacturing the same are described herein. Many specific details are provided in the following exemplary description to provide a more thorough understanding of aspects of the invention. However, it will be apparent to those skilled in the art that the disclosure may be implemented without incorporating all aspects of the specific details described herein. In other examples, specific features, quantities, or measurements well known to those skilled in the art are not described in detail so as not to obscure the invention. Readers should note that while examples of the invention are described herein, the entire scope of the claims and any equivalents defines the scope of the invention.

[0011] Aspects of this disclosure enable the construction and use of optical diffusers to induce and / or catalyze chemical reactions, commonly referred to as “photochemical reactions,” by enabling the execution of chemical reactions using light. Aspects enable the avoidance of hot spots and the minimization of shadowing while allowing for more uniform and controlled emission of chemicals. The wavelength of the light may be a single wavelength, multiple wavelengths, or a broad bandwidth of wavelengths, as produced by a laser. The wavelength may be visible light, IR, UV, microwave, and / or radio waves.

[0012] Broadly speaking, this disclosure involves the use of engineered optical diffusers that allow light refraction and prevent light from scattering through a material, in contrast to more conventional commercially available light diffusers. These conventional commercially available light diffusers are typically made of molded plastic or sandblasted or mechanically abraded glass (in flat and / or curved shapes). Sandblasting or other abrasion methods produce light scattering, and a moderate level of light diffusion can be achieved by so-called scattering.

[0013] Scattering is an optical phenomenon in which light strikes tiny, reflective, flat "facets" and reflects much of the light in random directions, both sideways and backward, away from the chemicals that are to be exposed to the light. Sandblasting, bead blasting, polishing, and sanding all create millions of very small facets, which are often invisible to the naked eye but are large compared to the wavelength of the light that shines on them. As a result, light, time, and ultimately cost are wasted, as typically at least half of the light that hits the outside of a container or window is reflected from the chemicals.

[0014] Figure 1 shows at least one embodiment of the present invention that depends on a photoreactive chemical substance in a transparent container, such as glass, or a container having one or more transparent windows. Non-limiting examples of containers suitable for photochemical reactions include reaction chambers, flasks, beakers, tubes, and bottles. In some embodiments, the container may be a reaction chamber, flask, beaker, etc., made of borosilicate glass. In another embodiment, the container may be a glass tube made of fused silica or borosilicate. In yet another embodiment, the container may be a sapphire tube. In yet another embodiment, the container may be a transparent plastic bottle or reaction chamber, that is, it may be made of a material that allows light to pass through transparently or semi-transparently. In certain embodiments, the container may be a metal or opaque plastic container with one or more glass windows (e.g., borosilicate, quartz glass, etc.), so that light does not pass through the container. In one or more embodiments, the light may be visible light or may be outside the visible spectrum (380-700 nm).

[0015] At least one aspect of the present invention involves placing an optical diffuser on one or both sides of a container wall or window, for example, the inner and / or outer surfaces. The engineered diffusing surface of the optical diffuser can be produced by controlled polishing and / or laser patterning of the surface(s), and then optionally by chemical etching to selectively pattern the surface(s). A thermal process can be used to passivate or "polish" the patterned surface(s), relieve stress on the glass, and strengthen the container. The resulting surface reflects far less light, allowing more light to reach the chemical (right side of the page, more light rays into, i.e., through, the diffuser and towards the photosensitive chemical), as shown in Figure 2B.

[0016] A properly designed optical diffuser does not rely on the scattering of light, but rather on the refraction of light. An optical diffuser strategically places millions of lenslets across the entire surface (possibly) of one or more inner and / or outer surfaces of a container or window. Typically, more than about 80% of the light that strikes the surface of the optical diffuser can pass through to the other side (e.g., transmitted light), allowing the chemicals contained within the container to absorb at least some of the transmitted light. In some embodiments, the amount of transmitted light can be about 80%–99%, 80%–95%, 85%–99%, or 85%–95%. The light used depends on the type of chemical reaction desired and is not limited to any wavelength of infrared, visible, or ultraviolet light required.

[0017] The term "approximately" when it precedes a number means a range of ±10% of that number. For example, "approximately 50" means 45 to 55, and "approximately 25" means 22.5 to 27.5. Furthermore, the phrases "approximately less than" a certain value or "approximately greater than" a certain value should be understood in light of the definition of the term "approximately" provided herein.

[0018] One or more embodiments of the present invention involve etching the surface of an abrasion surface using one or more acids to realize refractive microoptics (lenslets) on a desired surface of a glass processing chamber. In some embodiments, one or more acids may include hydrogen fluoride (HF) and ammonium hydrogen fluoride (ABF). To realize a suitable lenslet, the desired surface must be abraded in a controlled manner. This roughening can be achieved by several methods, including sandblasting and polishing.

[0019] Once the surface is polished, it is passivated by immersion in acid, removing sharp scattering surfaces. When this removal process is carried out for the appropriate time, concentration, and temperature, a desirable lenslet is obtained that can refract light (as opposed to undesirable scattering).

[0020] In the case of plastic-type transparent materials, a solvent can be used instead of an acid to passivate the surface. Similar to the acid for glass, the appropriate concentration and temperature vary depending on the type of plastic being used. Examples of solvents that may be used include acetone, γ-butyrolactone, and various hydroxides.

[0021] Alternatively, or in combination, in one or more aspects of the present invention, lasers, such as picosecond lasers and femtosecond lasers, can be used to pattern the surface, and microlenses and other shaped micro-optics can be formed on glass and plastic surfaces to create the desired refractive diffusion of light passing through these transparent materials.

[0022] Alternatively, or in combination, lithography is a common method in semiconductor processing for achieving well-controlled surfaces on optical surfaces and can be designed for specific light diffusion of light.

[0023] Another advantage of an optical diffuser is that its surface can be easily cleaned compared to a scattering diffuser. This is because a properly designed optical diffuser generally does not include features that capture small microcracks, fissures, and other contaminants, whereas conventional scattering diffusers contain numerous contamination traps that are nearly impossible to clean.

[0024] FIG. 3 shows a method of manufacturing at least one aspect of the present invention. As shown at 301, a scattering surface is formed on glass or plastic through any type of technique, including but not limited to abrasion. At 302, a microlens is formed on the glass or plastic using a solvent (for some plastics), or an acid, laser, or lithography for plastics and glass or other transparent materials. The microlens-type component (optical diffuser) is then connected to a container to form light diffusion and improve photon capture for the improvement of photochemical reactions.

[0025] Although the invention disclosed herein has been described by specific embodiments and uses thereof, many modifications and variations may be made by those skilled in the art without departing from the scope of the invention as described in the claims.

Claims

1. A method for manufacturing an optical diffuser to improve photon capture in order to improve photochemical reactions, Forming a lenslet on glass or plastic to remove sharp scattering surfaces and create an optical diffuser, Connecting the container to the optical diffuser and Includes, The container is configured to hold a chemical substance, The lenslet transmits light exceeding a certain percentage to the optical diffuser, and the percentage of light exceeds 80%. method.

2. A method for manufacturing an optical diffuser to improve photon capture in order to improve the photochemical reaction described in claim 1, Using an acid to form the lenslet on the glass or plastic to remove either of the sharp scattering surfaces. Methods that further include this.

3. A method for manufacturing an optical diffuser to improve photon capture in order to improve the photochemical reaction described in claim 1, Using a solvent, the lentret is formed on the plastic to remove any of the sharp scattering surfaces. Methods that further include this.

4. A method for manufacturing an optical diffuser to improve photon capture in order to improve the photochemical reaction described in claim 1, Using a laser, the lenslet is formed on the glass or plastic, and microoptics are formed on one or both sides of the glass or plastic. The laser further includes operating on a picosecond or femtosecond timeframe. method.

5. A method for manufacturing an optical diffuser to improve photon capture in order to improve the photochemical reaction described in claim 1, Using lithography, the lenslet is formed on the glass or plastic to form microoptics on one or both sides. Methods that further include this.

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