UV Sterilization Module Sealing for Uniform LED Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing UV-based sterilization apparatuses using mercury lamps pose environmental risks due to mercury content and suffer from inconsistent coupling forces leading to product reliability issues and potential damage to substrates.
Innovation Solution
A sterilization module design featuring a main body, light-transmissive member, inner sealing member, light emitting module, and inner holder, with specific fastening mechanisms and elastic materials to ensure uniform coupling and minimize substrate damage, enhancing product reliability and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mercury lamp is used for UV sterilization, then germicidal efficacy is achieved, but environmental problems occur due to mercury content
Solution Approach 1:
The patent extracts and removes the harmful mercury lamp from the sterilization system, replacing it with a UV-LED module that eliminates mercury content while maintaining UV sterilization functionality. This extraction of the harmful element resolves the environmental damage issue while preserving the essential germicidal effect.
Solution Approach 2:
The patent changes the fundamental parameter of the light source from mercury-based UV generation to solid-state UV-LED technology. This parameter change in the light source type eliminates mercury content and associated environmental hazards while maintaining the UV wavelength necessary for sterilization efficacy.
2Ease of manufacture
If conventional fastening methods are used to secure the light emitting module, then assembly is achieved, but coupling force is inconsistent leading to reliability issues
Solution Approach 1:
The patent replaces conventional mechanical fastening methods (screws, clips) with a magnetic coupling mechanism. The magnetic force provides consistent and uniform coupling force across multiple light emitting modules, eliminating the variability inherent in manual mechanical fastening while maintaining ease of assembly through simple magnetic attraction.
Solution Approach 2:
The magnetic coupling mechanism enables self-alignment and self-securing of the light emitting modules to the substrate. The magnetic force automatically adjusts to provide uniform coupling force without requiring external fastening tools or manual adjustment, ensuring consistent reliability across all modules.
3Stability of the object's composition
If the light emitting module is tightly secured to prevent movement, then positioning stability is improved, but substrate damage occurs
Solution Approach 1:
The patent introduces a flexible substrate as an intermediary layer between the rigid light emitting modules and the mounting surface. This flexible substrate absorbs mechanical stress and deformation, allowing tight positioning stability through magnetic coupling while preventing direct transmission of damaging forces to the rigid substrate, thus avoiding substrate damage.
Solution Approach 2:
The flexible substrate serves as a pre-positioned cushioning layer that protects the rigid substrate from mechanical damage before any stress is applied during assembly or operation. This beforehand cushioning allows secure mounting of light emitting modules while preventing force concentration that could damage the substrate.
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 achieves consistent coupling forces between components, reduces substrate damage, and improves product reliability by ensuring uniform assembly and tight sealing, while maintaining luminous efficiency and preventing moisture intrusion.
Implementation Method 1
a light-transmissive member disposed inside the main body to cover the opening and transmitting light therethrough
Implementation Method 2
an inner sealing member surrounding a side surface of the light-transmissive member and formed of an elastic material
Implementation Method 3
Ozone (O3) produced by UV wavelengths emitted from the mercury lamp has germicidal efficacy
Data Source
AI summary
A sterilization module includes a main body having an opening on the top surface thereof, a transparent member which is arranged on the inside of the main body so as to cover the opening, and through which light passes, an inner sealing member which is made of an elastic material and which covers the side surface of the transparent member, a light emitting module that comprises a substrate and a light emitting element installed on the upper surface of the substrate, and which emits light through the transparent member, and an inner holder which is fastened to the inner side surface of the main body and fixes the light emitting module to the inside of the main body.