Optical Component Sealing with Edge-Only Adhesive and Vacuum Treatment
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Solution Overview
Problem
Current optical components using nanoparticles lack efficient methods for sealing and integration with substrates, leading to issues with optical transparency, adhesion, and photoluminescent efficiency, particularly in solid-state lighting applications.
Innovation Solution
An optical component comprising a first substrate with quantum confined semiconductor nanoparticles, an adhesive material layer, and a second substrate, where the substrates are sealed together with an edge seal area that does not include optical material, ensuring uniformity and alignment, and optionally including a second optical material between the adhesive layer and the second substrate, with specific surface roughness and optical transparency properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nanoparticles are integrated with substrates using conventional sealing methods, then structural integration is achieved, but optical transparency and photoluminescent efficiency deteriorate due to air bubbles and oxygen permeation
Solution Approach 1:
The patent extracts and removes air bubbles from the sealing interface between substrates and nanoparticles through vacuum treatment during the sealing process. This eliminates the harmful air bubbles that would otherwise trap oxygen and reduce photoluminescent efficiency, while maintaining structural integration.
Solution Approach 2:
The patent creates an oxygen-barrier sealing environment using materials and processes that prevent oxygen permeation at the substrate-nanoparticle interface. By establishing an inert or oxygen-excluded environment during sealing, the photoluminescent efficiency is preserved without degradation from oxygen exposure.
2Strength
If adhesive material is applied to seal substrates, then structural bonding is achieved, but optical transparency deteriorates due to adhesive presence in the optical path
Solution Approach 1:
The patent applies adhesive material selectively only at the peripheral edges of the substrates rather than across the entire surface. This localized application provides sufficient structural bonding strength while keeping the central optical path free of adhesive, thereby maintaining optical transparency in the regions where light passes through.
Solution Approach 2:
The patent moves the adhesive material from the optical plane to the edge dimension, sealing substrates at their perimeters rather than across the full surface. This dimensional relocation of the adhesive function preserves optical transparency in the light path while achieving structural bonding at the boundaries.
3Reliability
If substrates are sealed together completely, then structural integrity is improved, but manufacturing complexity increases due to precision alignment requirements
Solution Approach 1:
The patent implements partial sealing at the edges rather than complete surface bonding. This edge-only sealing approach achieves sufficient structural integrity for the application while dramatically reducing alignment precision requirements, as only the peripheral regions need precise registration rather than the entire substrate surface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances optical transparency, adhesion, and photoluminescent efficiency, improving the performance of optical components in lighting devices by minimizing air bubbles and oxygen permeation, while maintaining the optical properties of the nanoparticles.
Implementation Method 1
a layer comprising an adhesive material disposed over the optical material and any portion of the first surface of the first substrate not covered by the optical material, and a second substrate disposed over the layer comprising the adhesive material, wherein the first and second substrates are sealed together by the layer comprising the adhesive material
Implementation Method 2
an optical material comprising quantum confined semiconductor nanoparticles disposed over a predetermined region of a first surface of the first substrate
Data Source
AI summary
An optical component is disclosed that comprises a first substrate, an optical material comprising quantum confined semiconductor nanoparticles disposed over a predetermined region of a first surface of the first substrate, a layer comprising an adhesive material disposed over the optical material and any portion of the first surface of the first substrate not covered by the optical material, and a second substrate disposed over the layer comprising an adhesive material, wherein the first and second substrates are sealed together. In certain embodiments, the optical component further includes a second optical material comprising quantum confined semiconductor nanoparticles disposed between the layer comprising the adhesive material and the second substrate. Method are also disclosed. Also disclosed are products including the optical component.