Quartz Glass UV LED Window With Integrated Lens and Hermetic Seal
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Solution Overview
Problem
Current technologies face challenges in developing a mercury-free, low-environmental-load, high-output ultraviolet LED with efficient light transmission and durability for deep ultraviolet wavelengths, particularly for UVB and UVC LEDs, due to limitations in substrate materials and window/lens materials that can handle the high energy and short wavelengths.
Innovation Solution
A silica glass member is developed for hermetic sealing of ultraviolet LEDs, featuring a homogeneously formed substrate with a plain surface for joining and lens-like convex portions for light processing, manufactured through a method that includes degreasing, purification, and oxygen-deficient defect repair, ensuring high transmittance and durability across the 200 nm to 400 nm wavelength range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a silicone resin lens is used for visible light LED, then the lens can be easily manufactured and mounted, but the resin undergoes deterioration and does not transmit ultraviolet light effectively
Solution Approach 1:
The patent changes the material parameter from organic silicone resin to inorganic quartz glass, which fundamentally alters the transmission and durability characteristics to enable UV light passage while maintaining structural integrity
Solution Approach 2:
The patent uses quartz glass as a composite material solution that combines the properties of high UV transmission, chemical inertness, and thermal stability, overcoming the limitations of single-material resin lenses
2Use of energy by moving object
If a quartz glass window plate is used, then light absorption is reduced, but light is diffused and a desired light intensity is not obtained
Solution Approach 1:
The patent transforms the flat window plate into a hemispherical lens shape, which focuses and concentrates the UV light rather than diffusing it, thereby maintaining high light intensity while preserving the low absorption properties of quartz glass
3Illumination intensity
If a hemispherical lens is created, then light intensity is improved, but the lens is difficult to mount on a package
Solution Approach 1:
The patent merges the hemispherical lens with a flat sealing plate into a single integrated quartz glass component, combining the light-focusing capability of the hemisphere with the mounting ease of a flat base, allowing direct attachment to the package substrate
Solution Approach 2:
The patent segments the quartz glass member into distinct functional zones: a hemispherical upper portion for light concentration and a flat lower portion for hermetic sealing and mounting, enabling both optical performance and ease of assembly
4Manufacturing precision
If purification treatment with chlorine or hydrogen chloride is performed, then the molded body is purified, but an optical absorption band is generated at 250 nm due to oxygen-deficient defects
Solution Approach 1:
The patent uses an oxygen-free inert atmosphere (nitrogen or vacuum) during the molding and heat treatment processes to prevent the formation of oxygen-deficient defects, thereby avoiding the generation of absorption bands at 250 nm while maintaining material purity
Solution Approach 2:
The patent changes the chemical environment parameter from oxidizing (chlorine/hydrogen chloride) to inert (nitrogen/vacuum), which prevents the formation of Si-Si bonds that cause UV absorption while still achieving purification of the quartz glass
5Use of energy by moving object
If oxygen-deficient defects are repaired with oxygen or water vapor atmosphere, then absorption at 250 nm is improved, but transmittance is reduced due to contamination with impurities
Solution Approach 1:
The patent performs preliminary prevention of oxygen-deficient defect formation by using an inert atmosphere from the outset during molding and heat treatment, eliminating the need for subsequent repair treatments that would require high temperature and risk contamination
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 silica glass member provides improved light extraction efficiency and durability for UVB and UVC LEDs, enabling hermetic sealing and efficient light transmission, addressing the limitations of existing materials and manufacturing methods.
Implementation Method 1
a silica glass member to be used for hermetic sealing of an ultraviolet LED configured to emit ultraviolet light in a wavelength range of from 200 nm to 350 nm
Implementation Method 2
a lens-like convex portion configured to process emitted light from the ultraviolet SMD LED element
Data Source
AI summary
Provided is a silica glass member for hermetic sealing of an ultraviolet SMD LED element to be suitably used for hermetic sealing of, and as a transmission window material for, a surface mount-type package (SMD) having an ultraviolet LED mounted thereon and configured to emit ultraviolet light in a wavelength range of from 200 nm to 350 nm. The silica glass member for hermetic sealing includes a silica glass substrate, which is homogeneously and integrally formed without an internal boundary, wherein the silica glass substrate has: a first surface on an inside opposed to an SMD LED element; and a second surface on an outside corresponding to the first surface, wherein an outer peripheral portion of the first surface has formed therein a substrate joining plain surface for joining to the container outer periphery joining plain surface, and wherein the second surface on the outside corresponding to the first surface has formed therein a lens-like convex portion configured to process emitted light from the ultraviolet SMD LED element.