The demands on LED optics are increasing: In addition to a high thermal load capacity and resistance to UV radiation, high scratch resistance and a longer targeted service life of more than 50,000 hours are desired properties. The material glass guarantees these high performance data. The production of LED optics made of glass is characterized by a large number of energy-intensive individual processes that lead to a relatively low material yield using environmentally harmful grinding and polishing agents.
The aim of "EFFEkT" was to develop an energy- and resource-efficient process chain for the wafer-based production of LED glass optics. Suitable glass heating and forming processes were developed, associated technical equipment was planned and set up. The metrological evaluation of the optics served to qualitatively assess the processes. For this purpose, process data was collected and prepared so that it is available for a comprehensive analysis. The data analysis served to support the process development and led to an energetic as well as economic evaluation of the process chain.
The consortium has succeeded in developing and manufacturing a suitable forming tool for the production of complex glass optics. Plant-integrated sensor technology and individual measurement strategies contributed to a complete characterization of the wafers. A database enabled the collection of relevant process and quality data, which are displayed by means of a graphical user interface. The selection and use of machine-learning algorithms made it possible to recognize patterns in process development and thus determine optimal process parameters for the production of glass wafers.
Federal Ministry for Economic Affairs and Energy