LSR Molding Silicon Optics| Revolutionize Nuclear Wastewater Detection System

Industry Background and Challenge

The nuclear wastewater treatment sector demands the highest standards in optical detection technology, especially when dealing with extreme environmental conditions. Traditional optical materials, such as glass and plastics, struggle to perform in such harsh environments. Glass optics are highly susceptible to thermal shock and can shatter under rapid temperature changes. Plastics, on the other hand, degrade quickly under high radiation, becoming brittle and yellowed over time. Meanwhile, metal sealing structures face the risk of corrosion from chemical exposure.

One Chinese nuclear facility supplier faced a particularly challenging project: developing an underwater monitoring system that required a large optics assembly, 100mm in diameter and 15mm in thickness. The optical material needed to maintain its stability for over five years while withstanding temperatures ranging from -40°C to 150°C, intense radiation, and submerged conditions. These extreme environmental demands posed significant challenges in terms of material weather resistance, sealing integrity, and precision molding.

YEJIA's Innovative Solution

After thorough evaluations and testing, YEJIA's engineering team selected Dow Corning MS1002, a specialized optical silicone rubber material, as the foundation of the solution. YEJIA's team then implemented a comprehensive, multi-layer defense system to address the unique challenges of this project:

1. Material Selection: The team chose imported Dow Corning optical silicone, known for its exceptional optical transmittance of 94% and outstanding performance in extreme environments, ensuring long-term reliability and clarity under intense radiation and temperature fluctuations.

2. Manufacturing Process: To guarantee the precision and durability of the optics, YEJIA employed state-of-the-art Arburg horizontal LSR (Liquid Silicone Rubber) injection molding technology. Coupled with a 2KM mixing system, the process utilized advanced mold temperature control (±0.5°C) and a multi-stage exhaust design. These measures effectively minimized defects, ensuring that the defect rate for bubbles in the 15mm thick optics remained well below 1%, far exceeding industry standards.

3. Sealing Design: To streamline the assembly process and improve performance, YEJIA’s silicon optics design included an integrated sealing ring structure. This simplified the overall assembly while delivering submersible-grade protection, ensuring that the optics could withstand high-pressure underwater environments without compromising performance.

Key Technical Breakthroughs

YEJIA's engineers achieved two major breakthroughs in overcoming the specific challenges of this project:

* Control of Optical Surface for Ultra-Thick optics: One of the key challenges with the 15mm thick optics was the risk of optical distortion, which could compromise the detection system's performance. To solve this, YEJIA employed Japanese-imported TOSHIBA UVM machinery for nano-level polishing. Additionally, YEJIA's in-house developed aspheric compensation algorithm further refined the optics, ensuring that light transmission efficiency met the exact specifications required by the client.

* Extreme Environmental Validation: YEJIA rigorously tested the optics to ensure they would perform reliably under the most demanding conditions. These tests included 5000 hours of dual-85 testing (85°C/85% humidity), 300°C steam shock tests, and vibration table simulations to validate the optics' durability and functionality under the extreme conditions encountered in nuclear power plants and wastewater facilities.

Achieved Customer Value

YEJIA's silicone optics solution delivered a revolutionary upgrade to the nuclear wastewater monitoring system. Through a complete vertical service—from material selection to mold design and mass production—YEJIA provided a seamless and reliable solution that addressed all technical challenges. The solution not only enhanced optical performance but also ensured the long-term durability of the components, enabling the customer to operate confidently in harsh, high-radiation environments.

With over 30 clients in the optical industry, YEJIA's silicone optics have proven to be a reliable, high-performance solution that stands up to the most extreme conditions. By providing exceptional optical transmittance and unrivaled environmental stability, YEJIA's silicone optics have helped clients overcome the challenges of nuclear wastewater detection, making monitoring systems more efficient, accurate, and durable.

For more details about our silicone optics solutions and to receive custom consultations, get in touch with us today!