Optical Disc Unit for UV Sterilizer Beam Control
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Solution Overview
Problem
Conventional ultraviolet sterilizers using TIR refractive lenses face limitations in beam angle expansion and sterilization effectiveness due to high material and processing costs, resulting in inadequate sterilization coverage and risk of light leakage.
Innovation Solution
An optical disc unit with a primary and secondary reflection portion, made from materials like polycarbonate, nylon, or aluminum, is designed to expand the beam angle of ultraviolet light emitted by LEDs, ensuring uniform irradiation and reducing light leakage by reflecting light through inclined surfaces and a donut-shaped body portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protrusion-shaped TIR refractive lens made of fused silica glass is used, then ultraviolet transmission function is improved, but manufacturing cost and processing complexity increase significantly
Solution Approach 1:
The patent replaces expensive fused silica glass with cheaper materials such as polycarbonate, acrylic, or nylon that can be molded using injection molding technology. While these materials have different optical properties, they achieve sufficient ultraviolet transmission for sterilization applications at a fraction of the cost of quartz glass TIR lenses.
Solution Approach 2:
The patent changes the optical design from relying on total internal reflection (TIR) in expensive glass to using reflective coatings on molded plastic surfaces. This parameter change in the optical mechanism allows the use of cheaper materials while maintaining functional performance for the intended application.
2Reliability
If a protrusion-shaped TIR refractive lens is used, then ultraviolet ray emission function is maintained, but beam angle expansion is limited
Solution Approach 1:
The patent introduces a secondary optical element (such as a reflective dish or additional lens) that redirects ultraviolet rays in a different spatial dimension. This allows the beam to spread in multiple directions beyond the limited cone angle of the primary LED, effectively expanding the sterilization coverage area without compromising the core emission function.
Solution Approach 2:
The optical system is divided into multiple segments: the primary LED emitter and secondary redirecting elements. This segmentation allows different parts of the system to perform specialized functions - the LED provides intense point-source emission while the secondary elements distribute the light over a wider area, achieving both focused emission and broad coverage.
3Area of stationary object
If multiple ultraviolet LEDs are installed to expand sterilization coverage, then beam angle coverage is improved, but manufacturing cost increases
Solution Approach 1:
The patent introduces an optical intermediary element (such as a reflective dish, lens array, or light guide) that acts as a mediator between a single LED source and the target area. This intermediary redirects and distributes the light from one inexpensive LED to cover a larger area, achieving the same effect as multiple LEDs but with lower component count and manufacturing complexity.
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 optical disc unit enhances sterilization efficiency by uniformly irradiating ultraviolet energy over a wider area, achieving effective disinfection within 10 minutes and reducing light leakage, while being cost-effective and suitable for mass production.
Implementation Method 1
An optical disc unit with a primary and secondary reflection portion... is designed to expand the beam angle of ultraviolet light emitted by LEDs... reflecting light through inclined surfaces
Implementation Method 2
the light from the ultraviolet LED passes through a lens, and the light is refracted through the lens so that the ultraviolet rays spread widely in an internal space
Implementation Method 3
the ultraviolet transmission function protrusion-shaped TIR refractive lens shape... forming the protrusion-shaped total internal reflection (TIR) refractive lens shape
Data Source
AI summary
An optical disc unit for an ultraviolet sterilizer, which is applied to the ultraviolet sterilizer, includes an ultraviolet light emitting diode (LED) to reflect light irradiated from the ultraviolet LED, including a body portion including a hollow and a primary optical unit fixedly coupled to an internal diameter surface in the hollow of the body portion and disposed in a direction perpendicular to an emission surface of the ultraviolet LED to reflect light irradiated from the ultraviolet LED, and according to an exemplary embodiment of the present disclosure, it is possible to enhance a sterilization ability by increasing a beam angle of light irradiated from the ultraviolet LED and uniformly irradiating the light and also reduce a risk of light leakage to the outside in a space to which the ultraviolet LED is applied.