UV-LED Sterilization Module With Integrated Waterproof Sealing
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Solution Overview
Problem
Conventional sterilization modules using UV light sources, such as mercury lamps, face challenges in miniaturization and leakage prevention, and often require separate spacers for waterproofing, which complicates manufacturing and increases costs.
Innovation Solution
A sterilization module design featuring a light source unit with a light emitting diode chip mounted on a circuit board, sealed by a transparent member and a sealing member, which forms a space to prevent leakage and miniaturize the module, using a conductive semiconductor layer and electrode for electrical connection, and a fastening member to secure the circuit board and sealing member, ensuring effective waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mercury lamp is used for sterilization, then sterilization efficiency is maintained, but environmental pollution occurs due to mercury leakage
Solution Approach 1:
The patent extracts and removes the mercury lamp from the sterilization module, replacing it with a UV-LED light source. This eliminates the source of mercury pollution while maintaining the sterilization function through UV-C emission from the LED chip.
Solution Approach 2:
The patent changes the light source parameter from mercury arc discharge to UV-LED electroluminescence. This parameter change eliminates mercury usage while achieving the same sterilization wavelength range (200-280nm) through solid-state lighting technology.
2Reliability
If a mercury lamp is used for sterilization, then sterilization function is achieved, but the module size increases
Solution Approach 1:
The patent segments the light source into a miniaturized UV-LED chip mounted on a small circuit board, replacing the bulky mercury lamp assembly. This segmentation enables compact integration while maintaining sterilization functionality.
Solution Approach 2:
The patent transitions from a large-volume mercury lamp to a planar UV-LED chip structure. This dimensional change from three-dimensional bulbous shape to two-dimensional flat chip enables significant size reduction while preserving the sterilization function.
3Reliability
If a mercury lamp is used for sterilization, then sterilization efficiency is maintained, but manufacturing cost increases
Solution Approach 1:
The patent adopts UV-LED chips that are cheaper to manufacture and replace than mercury lamps. Although LEDs have a finite lifespan, their lower initial cost and simpler disposal requirements reduce overall manufacturing and maintenance costs.
Solution Approach 2:
The patent replaces the mechanical mercury lamp system with a solid-state UV-LED system. This substitution eliminates complex glass envelopes, mercury filling, and ballast circuits, reducing manufacturing complexity and cost.
4Volume of moving object
If the light source is miniaturized, then module size is reduced, but sealing complexity increases
Solution Approach 1:
The patent merges the sealing function with the circuit board structure. The circuit board serves as both the electrical connection platform for the UV-LED chip and the sealing surface that creates the UV-transmissive window, eliminating separate sealing components.
Solution Approach 2:
The transparent window serves multiple functions: it seals the light source assembly, provides UV transmission for sterilization, and acts as the emission aperture. This multi-functionality reduces the number of separate components needed.
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 design enhances miniaturization, reduces manufacturing costs, and improves waterproofing efficiency by integrating the light source and sealing components, while maintaining effective UV transmission for sterilization.
Implementation Method 1
a light source unit irradiating ultraviolet light toward the transparent member, and the light source unit includes a circuit board and a light emitting diode chip mounted on the circuit board
Implementation Method 2
a transparent member disposed on the ultraviolet outlet and configured to transmit ultraviolet light
Data Source
AI summary
A sterilization module including a main body, a circuit board disposed in the main body, a light source disposed on the circuit board to emit sterilizing light, and a transparent unit to protect the light source from an outside and including a material that transmits the sterilizing light, in which the light source includes a mesa including a first semiconductor layer, an active layer, and a second semiconductor layer, a first electrode electrically connected to the first semiconductor layer, and a second electrode disposed on the second semiconductor layer and electrically connected to the second semiconductor layer, in which the first electrode includes a first contact region disposed on the outer area of the first semiconductor layer and a second contact region at least partially surrounded by the mesa, and a distance between the transparent unit and the circuit board is greater than a height of the light source.