Transparent Sealing Structure for UV-Protected Optical Packages

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Solution Overview

Problem

Conventional optical components face durability issues due to ultraviolet light irradiation on organic adhesive layers, leading to increased manufacturing costs and complexity when using specialized adhesives or metallic bonding layers.

Innovation Solution

A transparent sealing member is designed with a transparent body joined via an organic adhesive layer on the mounting substrate, featuring a concave portion open at the bottom to redirect ultraviolet light away from the adhesive, thereby enhancing package durability and light extraction efficiency while using inexpensive organic adhesives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If an organic adhesive layer is used to join the mounting substrate and lid member, then the manufacturing process is simple and cost-effective, but the adhesive layer deteriorates due to ultraviolet light irradiation, reducing package durability

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidpackage durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces a light-shielding layer that segments the optical path, separating the ultraviolet light emitted by the optical element from the organic adhesive layer. This segmentation prevents direct irradiation of the adhesive while maintaining the overall package structure and manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The light-shielding layer acts as an intermediary element between the optical element and the organic adhesive layer. It blocks ultraviolet light from reaching the adhesive while allowing the adhesive to continue joining the mounting substrate and lid member, thus protecting the adhesive without complicating the manufacturing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a specialized adhesive mixture (silicone resin and fluoropolymer) is used to resist ultraviolet light, then the package durability is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvepackage durabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts the ultraviolet resistance function from the adhesive material itself and relocates it to a separate light-shielding layer. This allows the use of inexpensive organic adhesives without specialized UV-resistant additives, while still achieving the necessary protection against ultraviolet degradation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The light-shielding layer serves as a sacrificial or disposable protective element that absorbs the ultraviolet radiation damage instead of the expensive specialized adhesive. By using a simple light-shielding structure rather than costly UV-resistant adhesive formulations, the overall manufacturing cost is reduced while maintaining package durability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If a metallic bonding layer such as solder is used to join the lid member, then the bond strength is improved, but the manufacturing process becomes complicated and costly

Engineering Contradiction:

Improvebond strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the metallic bonding system (soldering or brazing) with an organic adhesive bonding system combined with a light-shielding layer. This substitution maintains sufficient bond strength for sealing the package while dramatically simplifying the manufacturing process, eliminating the need for high-temperature bonding equipment and complex metallurgical processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 effectively prevents ultraviolet light from irradiating the organic adhesive, improving the durability of the optical component package and enhancing light extraction efficiency while maintaining cost-effectiveness.

Implementation Method 1

there exists a light component emitted toward the aforementioned joined portion. In particular, the latter one of these light components is guided in a peripheral portion of the lid member 110, and impinges on the adhesive layer 112

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

the transparent body includes a concave portion which is open at a bottom thereof... redirect ultraviolet light away from the adhesive

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS12278317B2Transparent sealing member and optical component

Publication Date: 2025.04.15 NGK INSULATORS LTD

AI summary

The present invention relates to a transparent sealing member and an optical component. The present invention is a transparent sealing member (10A) used in an optical component (100A) provided with a package (16A) having at least one optical element (14) emitting ultraviolet light (12) and a mount board (18) to which the optical element is mounted. The transparent sealing member (10A) is provided with a transparent body (24) joined on the mount board (18) via an organic adhesion layer (20), and the transparent body (24) has a housing space (26) in a lower surface opening.