Quartz Window Material With Rough Surface for UV Light Distribution
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Solution Overview
Problem
Current window materials for ultraviolet LEDs, particularly in the deep ultraviolet region, face challenges in shaping synthetic quartz glass into lens forms due to its difficulty in processing, and existing antireflection methods fail to reliably control light distribution and maintain high total light transmittance over time.
Innovation Solution
A window material comprising a synthetic quartz glass substrate with a flat plate shape and a three-layer antireflection film, including Al2O3, HfO2, and MgF2 or SiO2 thin films, which provides a rough surface for effective light scattering and high total light transmittance, facilitating easy processing and long-term stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If synthetic quartz glass is used as window material for UV-LED sealing, then good transmittance of short-wavelength light is achieved, but difficulty in cutting and shaping into lens form increases
Solution Approach 1:
The patent divides the window material into two functional parts: a synthetic quartz glass substrate for UV transmittance and a resin layer for light distribution control. This segmentation allows each material to perform its optimal function without requiring the quartz glass to be difficultly shaped into a lens form.
Solution Approach 2:
The resin layer acts as an intermediary between the quartz glass substrate and the external environment. It provides the light distribution control function that would otherwise require complex shaping of the quartz glass, while the quartz glass maintains its simple flat plate shape for easy manufacturing.
2Shape
If a lens-shaped window material is formed to control light distribution properties, then light distribution control is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent separates the light distribution control function from the structural window material by introducing a dedicated resin layer. This allows the window to maintain a simple flat plate shape while achieving lens-like light distribution control through the resin layer's refractive properties.
Solution Approach 2:
The patent controls light distribution by adjusting parameters of the resin layer such as its refractive index, thickness, and positioning relative to the LED chip, rather than changing the physical shape of the entire window assembly. This provides manufacturing simplicity while achieving optical control.
3Illumination intensity
If antireflection film is deposited on quartz surface to improve transmittance, then theoretical reflectance reduction is achieved, but reliability for total light transmittance in actual use is insufficient
Solution Approach 1:
The patent changes the approach from depositing antireflection films to controlling the refractive index and thickness parameters of a resin layer. This parameter-based control provides more reliable and predictable total light transmittance performance in actual LED applications.
Solution Approach 2:
The resin layer serves as an intermediary that optimizes light transmission from the LED chip through the window. Its refractive index is selected to match or complement the quartz glass, minimizing reflections at interfaces and maximizing total light transmittance without requiring complex antireflection film structures.
4Illumination intensity
If moth-eye antireflection structure with silica particles is used, then ultraviolet light reflection is inhibited, but degree of freedom in controlling light distribution properties is limited
Solution Approach 1:
The patent separates the antireflection function (achieved through resin layer refractive index control) from the light distribution control function (achieved through resin layer thickness and positioning). This segmentation provides flexibility in optimizing both functions independently.
Solution Approach 2:
The patent uses parameter control (refractive index, thickness, positioning) of the resin layer to achieve both antireflection and light distribution control, providing greater adaptability and versatility compared to fixed moth-eye structures.
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 enables reliable control of light distribution properties, maintains high total light transmittance, and ensures long-term stability, making it suitable for ultraviolet LEDs, particularly in the deep ultraviolet region.
Implementation Method 1
at least one of the main surfaces being a rough surface
Implementation Method 2
an antireflection film formed on the at least one main surface of the synthetic quartz glass substrate
Data Source
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AI summary
A window material for an optical element, including: a synthetic quartz glass substrate having a flat plate shape and having main surfaces through which light is transmitted, at least one of the main surfaces being a rough surface; and an antireflection film formed on the at least one main surface of the synthetic quartz glass substrate, the main surface being the rough surface. The window material for an optical element of the present invention is easy in shape processing, undergoes little temporal change in a wide wavelength region and is stable over a long period of time, and has high total light transmittance of distributed light.