Patent Application
20160096776
1. Field of the Invention
The present invention relates to a window material for an ultraviolet light emitting device (ultraviolet-ray-emitting element) and a method for producing the same, the window material having an excellent transmittance of an ultraviolet light from an ultraviolet light emitting device for emitting an ultraviolet light having a wavelength of 300 nm or less, such as a light emitting diode, a laser diode, a discharge lamp, or the like.
2. Description of the Related Art
Ultraviolet lights have been used for various purposes depending on the wavelengths. Particularly, an ultraviolet light having a wavelength within a region of 280 nm or less, which is called UV-C, exhibits a high disinfecting capability, and therefore has been used for bacterial disinfection or eradication (see Japanese Laid-Open Patent Publication No. 2008-091623).
An ultraviolet light emitting device is known as one of the light sources for emitting an ultraviolet light. The ultraviolet light emitting device is covered with a window material of a light transmitting material for protecting the device. A glass material is conventionally used as the light transmitting material for the ultraviolet light emitting device, and is composed of a high-silica glass (quartz) or the like in view of productivity, cost, and strength (see Japanese Laid-Open Patent Publication No. 2000-349348).
Meanwhile, the ultraviolet light emitting device is broken or deteriorated at a high temperature. Therefore, the ultraviolet light emitting device is required to be capable of efficiently releasing its heat to improve the emission efficiently (see Japanese Laid-Open Patent Publication No. 2002-289925).
As described above, the quartz has been used as the window material for the ultraviolet light emitting device. However, the quartz has a low thermal conductivity of approximately 1 W/m·K, and cannot efficiently release the heat of the device. Therefore, the ultraviolet light emitting device using the quartz is likely to have a high temperature and to be broken or deteriorated.
Furthermore, the quartz exhibits a lower front total light transmittance of a shorter wavelength light. Particularly, the quartz exhibits a significantly low front total light transmittance of a light having a wavelength of 300 nm or less.
In view of the above problems, an object of the present invention is to provide a window material, which has a high thermal conductivity, exhibits a high transmittance of an ultraviolet light having a wavelength of 300 nm or less, and is suitable for use in an ultraviolet light emitting device, and a method for producing the window material.
[1] A window material for an ultraviolet light emitting device for emitting an ultraviolet light having a wavelength of 300 nm or less, according to a first aspect of the present invention, is mounted on at least an ultraviolet light emitting side of the ultraviolet light emitting device, wherein the window material contains a translucent alumina, and has a surface with an average grain diameter of 6 to 60 μm.
[2] In the first aspect of the present invention, the window material may contain a substrate that has a plate shape with a thickness of 2.0 mm or less and has one surface and the other surface facing the one surface. The thickness may be 1.5 mm or less, or 1.0 mm or less. The thickness is preferably 0.5 mm or less, more preferably 0.3 mm or less.
[3] In this case, the one surface of the substrate may be a surface from which ultraviolet light outgoes, and at least the one surface may have a surface roughness Ra of 0.03 μm or less.
[4] Alternatively, the other surface may be a surface into which ultraviolet light enters, and at least the other surface may have a surface roughness Ra of 0.2 μm or more, preferably 0.2 to 0.6 μm.
[5] Alternatively, it is preferred that the one surface and the other surface of the substrate have different surface roughnesses.
[6] In this case, the one surface may be a surface from which ultraviolet light outgoes, the other surface may be a surface into which ultraviolet light enters, the one surface may have a surface roughness Ra of 0.03 μm or less, and the other surface may have a surface roughness Ra of 0.2 pin or more, preferably 0.2 to 0.6 μm.
[7] A production method according to a second aspect of the present invention is for producing the window material according to the first aspect of the present invention, and includes the step of performing a gel casting process or a tape casting process to prepare a substrate which contains a translucent alumina and has one surface and the other surface facing the one surface.
[8] In the second aspect of the present invention, the one surface and the other surface of the substrate may have different surface roughnesses. In this case, for example, the one surface or the other surface of the substrate may be subjected to a mirror polishing or grinding treatment. Alternatively, a green body to be processed into the substrate may be prepared by the gel casting process or the tape casting process, and then sintered while contacting different types of setters respectively with one surface and the other surface of the green body.
[9] In the second aspect of the present invention, the method may further include the step of mirror-polishing at least the one surface of the substrate to obtain a surface roughness Ra of 0.03 μm or less.
[10] Alternatively, the method may further include the step of increasing at least a surface roughness of the other surface of the substrate. In this step, at least the other surface of the substrate may be ground. Alternatively, the green body may be sintered while different types of setters are in contact respectively with the one surface and the other surface of the green body. For example, one setter that is in contact with the other surface may have a surface roughness larger than that of another setter that is in contact with the one surface, and thus the other surface of the substrate may have a larger surface roughness.
[11] Alternatively, the method may further include the step of mirror-polishing the one surface of the substrate to obtain a surface roughness Ra of 0.03 μm or less, and the step of increasing a surface roughness of the other surface of the substrate. In this step, at least the other surface of the substrate may be ground. Alternatively, in the sintering of the green body, one of the setters that is in contact with the other surface of the green body may have a surface roughness larger than that of another setter that is in contact with the one surface, and thus the other surface of the substrate may have a larger surface roughness. Then, the one surface of the substrate may be mirror-polished to obtain the surface roughness Ra of 0.03 μm or less.
The window material of the present invention can exhibit a high transmittance of an ultraviolet light having a wavelength of 300 nm or less, and can be suitable for use in the ultraviolet light emitting device. Furthermore, the translucent alumina substrate has a high thermal conductivity of 30 W/m·K or more, and thus can efficiently release heat generated in operation of the ultraviolet light emitting device. Consequently, the window material can prevent the ultraviolet light emitting device from being broken or deteriorated due to temperature rise.
Furthermore, the method of the present invention is capable of easily producing the window material, which can exhibit a high transmittance of an ultraviolet light having a wavelength of 300 nm or less and can efficiently release heat generated in operation of the ultraviolet light emitting device.
The above and other objects, features, and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example.
Several embodiment examples of a window material for an ultraviolet light emitting device and a production method therefor according to the present invention will be described below with reference to
As shown in
The window material 10 contains an alumina substrate (a translucent alumina substrate 14).
The translucent alumina substrate 14 has a plate shape with a thickness t of 0.3 mm or less, and has a surface from which the ultraviolet light 12 outgoes (the light outgoing surface 16a: one surface), and a surface into which the ultraviolet light 12 enters (the light entering surface 16b: the other surface) disposed face-to-face with the light outgoing surface 16a. For example, the planar shapes of the surfaces may be selected from triangular shapes, rectangular shapes, square shapes, circular shapes, elliptical shapes, polygonal shapes, and the like depending on a shape of a case to which the ultraviolet light emitting device is mounted.
The average grain diameter of the surface of the translucent alumina substrate 14 is preferably 6 to 60 μm, more preferably 6 to 20 μm. The average grain diameter of the surface was measured as follows. A portion was selected at random in the surface and observed by an optical microscope at 200-fold magnification, and the number of the crystals located on a 0.7-mm line segment was counted. Then, a value obtained by multiplying 0.7 by 4/π was divided by the counted crystal number to obtain the average grain diameter.
In particular, in the translucent alumina substrate 14 according to this embodiment, the light outgoing surface 16a and the light entering surface 16b have different surface roughnesses. Specifically, the light outgoing surface 16a may have a surface roughness Ra (arithmetic average roughness) of 0.03 μm or less, and the light entering surface 16b may have a surface roughness Ra of 0.2 μm or more, preferably 0.2 to 0.6 μm. Alternatively, the light outgoing surface 16a and the light entering surface 16b may have different surface roughnesses Ra of 0.2 μm or more, preferably 0.2 to 0.6 μm.
A process for preparing the translucent alumina substrate 14 is not particularly limited, and may be any process such as a doctor blade process (a tape casting process), an extrusion process, or a gel casting process. The process for preparing the translucent alumina substrate 14 is preferably a gel casting process or a tape casting process, particularly preferably a gel casting process.
In a preferred embodiment, a slurry, which contains a starting material powder (ceramic powder) including an alumina powder, a dispersion medium, and a gelling agent, is cast into a mold and then converted to a gel to prepare a green body. The green body is sintered to obtain the translucent alumina substrate 14 (see Japanese Laid-Open Patent Publication No. 2001-335371).
The starting material is particularly preferably prepared by adding 150 to 1000 ppm of an auxiliary agent to a high-purity alumina powder having a purity of 99.9% or more (preferably 99.95% or more). Examples of such high-purity alumina powders include those available from Taimei Chemicals Co., Ltd. The auxiliary agent is preferably magnesium oxide, and examples thereof further include ZrO2, Y2O3, La2O3, and Sc2O3.
The gel casting processes include the following processes.
(1) An inorganic substance powder, a gelling agent of a prepolymer such as a polyvinyl alcohol, an epoxy resin, a phenol resin, etc., and a dispersing agent are dispersed in a dispersion medium to prepare a slurry. Then, the slurry is cast into a mold, and thereafter is three-dimensionally crosslinked by a crosslinking agent, whereby the slurry gelates and solidifies.
(2) A slurry is solidified by chemically bonding an organic dispersion medium having a reactive functional group and a gelling agent. This process is disclosed in Japanese Laid-Open Patent Publication No. 2001-335371 by the present applicant.
Several production methods (first to seventh production methods) for producing the window material 10 (the translucent alumina substrate 14) of this embodiment will be described below with reference to the process charts of
In the first production method, in Step S1 in
Then, in Step S2, the alumina green body is sintered to produce the translucent alumina substrate 14 having thickness of 0.3 mm or less, i.e. the window material 10.
In the second production method, in Step S101 in
In Step S102, the alumina green body is sintered to prepare the translucent alumina substrate 14 having a thickness of more than 0.3 mm.
Then, in Step S103, only the light outgoing surface 16a of the translucent alumina substrate 14 is mirror-polished, whereby the surface roughness Ra is reduced to 0.03 μm or less, to produce the translucent alumina substrate 14 having a thickness of 0.3 mm or less, i.e. the window material 10.
In the third production method, in Step S201 in
In Step S202, the alumina green body is sintered to prepare the translucent alumina substrate 14 having a thickness of more than 0.3 mm.
Then, in Step S203, only the light outgoing surface 16a of the translucent alumina substrate 14 is mirror-polished, whereby the surface roughness Ra is reduced to 0.03 μm or less. Furthermore, only the light entering surface 16b of the translucent alumina substrate 14 is ground such that the surface roughness Ra falls within a range of 0.2 to 0.6 μm, to produce the translucent alumina substrate 14 having a thickness of 0.3 mm or less, i.e. the window material 10.
The following process may be carried out instead of the above treatment of grinding the light entering surface 16b of the translucent alumina substrate 14. That is, the following setters are used in the sintering of the alumina green body in Step S202. One of the setters that is in contact with the other surface of the alumina green body (corresponding to the light entering surface) has a surface roughness larger than that of the other setter that is in contact with the one surface (corresponding to the light outgoing surface). Thus, the surface roughness Ra of the light entering surface 16b of the translucent alumina substrate 14 is controlled within a range of 0.2 to 0.6 μm by the sintering process. Then, only the light outgoing surface 16a of the translucent alumina substrate 14 is mirror-polished to obtain a surface roughness Ra of 0.03 μm or less.
In the fourth production method, in Step S301 in
In Step S302, the alumina green body is sintered to prepare the translucent alumina substrate 14 having a thickness of more than 0.3 mm.
Then, in Step S303, the light outgoing surface 16a and the light entering surface 16b of the translucent alumina substrate 14 are both mirror-polished, whereby the surface roughnesses Ra are reduced to 0.03 μm or less, to produce the translucent alumina substrate 14 having a thickness of 0.3 mm or less, i.e. the window material 10.
In the fifth production method, in Step S401 in
In Step S402, the alumina green body is sintered to prepare the translucent alumina substrate 14 having a thickness of more than 0.3 mm.
Then, in Step S403, only the light entering surface 16b of the translucent alumina substrate 14 is mirror-polished, whereby the surface roughness Ra is reduced to 0.03 μm or less, to produce the translucent alumina substrate 14 having a thickness of 0.3 mm or less, i.e. the window material 10.
In the sixth production method, in Step S501 in
In Step S502, the alumina green body is sintered to prepare the translucent alumina substrate 14 having a thickness of more than 0.3 mm.
Then, in Step S503, the light outgoing surface 16a and the light entering surface 16b of the translucent alumina substrate 14 are both ground, whereby the surface roughnesses Ra are controlled within a range of 0.2 to 0.6 μm, to produce the translucent alumina substrate 14 having a thickness of 0.3 mm or less, i.e. the window material 10.
The following process may be carried out instead of the above treatment of grinding the light outgoing surface 16a and the light entering surface 16b of the translucent alumina substrate 14. That is, in the sintering of the alumina green body in Step S502, setters having a large surface roughness are brought into contact with the one surface and the other surface of the alumina green body. The setters may be of different types. Thus, the surface roughnesses Ra of the light outgoing surface 16a and the light entering surface 16b of the translucent alumina substrate 14 are controlled within a range of 0.2 to 0.6 μm by the sintering process. The light outgoing surface 16a and the light entering surface 16b may have the same or different surface roughnesses.
In the seventh production method, in Step S601 in
In Step S602, the alumina green body is sintered to prepare the translucent alumina substrate 14 having a thickness of more than 0.3 mm.
Then, in Step S603, the light outgoing surface 16a of the translucent alumina substrate 14 is ground, whereby the surface roughness Ra is controlled within a range of 0.2 to 0.6 μm, to produce the translucent alumina substrate 14 having a thickness of 0.3 mm or less, i.e. the window material 10.
The following process may be carried out instead of the above treatment of grinding the light outgoing surface 16a of the translucent alumina substrate 14. That is, the following setters are used in the sintering of the alumina green body in Step S602. One of the setters that is in contact with the one surface of the alumina green body (corresponding to the light outgoing surface) has a surface roughness larger than that of the other setter that is in contact with the other surface (corresponding to the light entering surface). Thus, the surface roughness Ra of the light outgoing surface 16a of the translucent alumina substrate 14 is controlled within a range of 0.2 μm or more, preferably 0.2 to 0.6 μm, by the sintering process.
As described above, in the window material 10 of this embodiment, the translucent alumina substrate 14 is used, and the average grain diameter of the surface is controlled within a range of 6 to 60 μm, preferably 6 to 20 μm. As a result, the window material 10 can exhibit a high transmittance of ultraviolet light having a wavelength of 300 nm or less, and can be suitably used in the ultraviolet light emitting device. Furthermore, the translucent alumina substrate 14 has a high thermal conductivity of 30 W/m·K or more. Therefore, the window material 10 can efficiently release heat generated in operation of the ultraviolet light emitting device to thereby prevent the device from being broken or deteriorated due to temperature rise.
In the translucent alumina substrate 14, the surface roughness Ra of the light outgoing surface 16a may be 0.03 μm or less, and may be 0.2 μm or more, preferably 0.2 to 0.6 μm. Similarly, the surface roughness Ra of the light entering surface 16b may be 0.03 μm or less, and may be 0.2 μm or more, preferably 0.2 to 0.6 μm.
In the translucent alumina substrate 14, it is particularly preferred that the light outgoing surface 16a should have a surface roughness Ra of 0.03 μm or less, and the light entering surface 16b should have a surface roughness Ra of 0.2 to 0.6 μm.
In Examples 1 to 6 and Comparative Examples 1 to 3, surface roughness measurement and transmittance evaluation were carried out. Details and evaluation results of Examples 1 to 6 and Comparative Examples 1 to 3 are shown in Tables 1 to 3 to be hereinafter described.
Surface roughnesses of light outgoing surfaces and light entering surfaces in measurement samples (of Examples 1 to 6 and Comparative Examples 1 to 3) were measured by using a laser microscope (VK-9700 available from Keyence Corporation) at 500-fold magnification.
Transmittances were evaluated with respect to front total light transmittances. Specifically, average transmittances within a measurement wavelength region of 200 to 280 nm and transmittances at a particular wavelength of 210 nm were evaluated. The evaluation wavelength region was selected because UV-C has a wavelength of 280 nm or less, and a light having a wavelength of 200 nm or less is generally absorbed in the air, and thus is a measurement limit of a measurement apparatus. Furthermore, because more significant effects are obtained at a shorter wavelength in Examples, the wavelength of 210 nm was selected as the particular wavelength for the evaluation and the transmittances at the particular wavelength of 210 nm were also used as evaluation values.
As shown in
The ultraviolet light 12 having a wavelength of 200 to 280 nm was emitted from the light source 20 to the light entering surface of the measurement sample fixed to the slit plate 26. The ultraviolet light 12 transmitted through the measurement sample and exiting the light outgoing surface was detected by the detector 22.
The front total light transmittance was calculated from the ratio (I/I0) of the intensity (I) of the ultraviolet light 12 transmitted through the measurement sample to the intensity (I0) of the ultraviolet light 12 measured without the fixed measurement sample.
According to the first production method shown in
Specifically, 500 ppm of a magnesium oxide powder was added to a high-purity alumina powder having a purity of 99.99% or more, a BET surface area of 9 to 15 m2/g, and a tap density of 0.9 to 1.0 g/cm2. The starting material powder was formed by a gel casting process. 100 parts by weight of this powder, 40 parts by weight of a dispersion medium (dimethyl malonate), 8 parts by weight of a gelling agent (modified 4,4′-diphenylmethane diisocyanate), 0.1 to 0.3 parts by weight of a reaction catalyst (triethylamine), and a nonionic dispersing agent were mixed.
The slurry was prepared at 20° C. by the steps of dispersing the starting material powder and the dispersing agent in the dispersion medium, dispersing the gelling agent therein, and then adding the reaction catalyst thereto. The slurry was cast into the mold and left for 2 hours to prepare the gel. The gelled alumina green body was released from the mold and dried at 60° C. to 100° C. Then, the green body was degreased at 1100° C. for 2 hours and sintered in a hydrogen atmosphere.
The translucent alumina substrate 14 had a thickness t of 0.3 mm and had a surface with an average grain diameter of 20 μm. Both of the light outgoing surface 16a and the light entering surface 16b had the same surface roughness Ra of 0.3 μm.
The front total light transmittance of the translucent alumina substrate 14 was measured. As a result, the translucent alumina substrate 14 exhibited an average transmittance of 89% in the wavelength region of 200 to 280 nm, and exhibited a transmittance of 90% at a wavelength of 210 nm.
A translucent alumina substrate 14 of Example 2 was produced in the same manner as Example 1 except that the average grain diameter of the alumina powder (or the sintering temperature or the sintering time) was changed. The translucent alumina substrate 14 had a thickness t of 0.3 mm and had a surface with an average grain diameter of 12 μm. Both of the light outgoing surface 16a and the light entering surface 16b had the same surface roughness Ra of 0.2 μm. The front total light transmittance of the translucent alumina substrate 14 was measured. As a result, the translucent alumina substrate 14 exhibited an average transmittance of 90% in the wavelength region of 200 to 280 nm, and exhibited a transmittance of 95% at a wavelength of 210 nm.
According to the second production method shown in
According to the third production method shown in
According to the fourth production method shown in
According to the fifth production method shown in
The front total light transmittance of a quartz substrate having a diameter of 20 mm and a thickness of 0.5 mm was measured. As a result, the quartz substrate exhibited an average transmittance of 88% in the wavelength region of 200 to 280 nm, and exhibited a transmittance of 86% at a wavelength of 210 nm.
A translucent alumina substrate 14 of Comparative Example 2 was produced in the same manner as Example 1 except that the average grain diameter of the alumina powder (or the sintering temperature or the sintering time) was changed. The translucent alumina substrate 14 had a thickness t of 0.3 mm and had a surface with an average grain diameter of 5 μm. Both of the light outgoing surface 16a and the light entering surface 16b had the same surface roughness Ra of 0.1 μm. The front total light transmittance of the translucent alumina substrate 14 was measured. As a result, the translucent alumina substrate 14 exhibited an average transmittance of 67% in the wavelength region of 200 to 280 nm, and exhibited a transmittance of 68% at a wavelength of 210 nm.
A translucent alumina substrate 14 of Comparative Example 3 was produced in the same manner as Example 1 except that the average grain diameter of the alumina powder (or the sintering temperature or the sintering time) was changed. The translucent alumina substrate 14 had a thickness t of 0.3 mm and had a surface with an average grain diameter of 65 μm. As a result of observing the sintered translucent alumina substrate 14, a crack was found. Therefore, the surface roughness and the front total light transmittance could not be measured.
As is clear from Tables 1 to 3, it is preferred that the window material 10 contains a material of a translucent alumina and the surface has an average grain diameter of 6 to 60 μm. The quartz of Comparative Example 1 exhibits more excellent front total light transmittance evaluation results as compared with Example 5. However, the quartz has a low thermal conductivity of approximately 1 W/m·K and cannot release heat efficiently. Consequently, the ultraviolet light emitting device containing the quartz is likely to be broken or deteriorated due to temperature rise disadvantageously.
In Examples 1 to 6, excellent evaluation results were achieved. As is clear from the results of Examples 1, 2, and 5, it is preferred that when the light outgoing surface and light entering surface of the translucent alumina substrate have the same surface roughness, the surfaces should not be mirror-polished.
Furthermore, as is clear from the excellent evaluation results of Examples 3 and 4, it is further preferred that the light outgoing surface and the light entering surface of the translucent alumina substrate should have different surface roughnesses, and it is particularly preferred that the light outgoing surface should have a surface roughness Ra of 0.03 μm or less and the light entering surface should have a surface roughness Ra of 0.2 to 0.6 μm.
It is to be understood that the window material and the production method of the present invention are not limited to the above embodiments, and various changes and modifications may be made therein without departing from the scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-123466 | Jun 2013 | JP | national |
This application is a Continuation of International Application No. PCT/JP2014/065317 filed on Jun. 10, 2014, which is based upon and claims the benefit of priority from Japanese Patent Application No. 2013-123466 filed on Jun. 12, 2013, the contents all of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2014/065317 | Jun 2014 | US |
| Child | 14965546 | US |
