CAPABILITIES

Yamamura Photonics has created a wide range of technologies based on experiences of product development and mass-production. We propose the best solution for every customer's requirement throughout these technologies, such as glass processing, joining, optical designing, etc.

01

GLASS PROCESSING

SELLING POINT

Yamamura Photonics' glass processing technology has been cultivated through many years of business activities. Despite being processed by human hands, we are good at high-precision processing, and we have a track record of processing a wide variety of shapes from 1/2 inch to 10 inch size.

EXAMPLES OF PROCESSING METHOD

Blow processing (including mold design)

Press working

Tube pulling

Lathe manufacturing

In addition to processing glasses by the methods described above, we also have abundant experience in air-sealing processing of metal and glass, such as embedding metal terminals. We also have a lot of design know-how regarding the sealing shape, and it is possible to realize the air-sealing process with excellent strength because of the design to reduce applied stress. By taking advantage of technologies such as ring seals that join ring-shaped metal and cylindrical glass, or disc seals that join ring-shaped metal and disk-shaped glass, we provide products for medical, analytical, and infrastructure-related equipment requiring high vacuum.

PRODUCT EXAMPLES

X-ray tubes for medical or industrial usage

Image intensifier tube

Enclosure for vacuum interrupter

Vacuum container for electron tubes

Glass stem

Yamamura Photonics is also focusing on inheriting glass processing technology. We are working to continuing the glass business and reinforcing the production system in the future. Also, we are working on raising the skills of existing technicians and making them multi-skilled mainly through OJT, not only training new technicians. We are continuously building a work environment where we can actively respond to new inquiries.

02

JOINING

Yamamura Photonics' joining technology started with glass to metal sealing technology (GTMS). As a result of working on various product developments over the years, three joining technologies have now been established.

Direct joining of glass and metal

Joining using low melting point sealing glass

Joining using Hybrid resin adhesive

  HERMETICITY STRENGTH MATCHING OF CTE JOINING TEMPERATURE
DIRECT SEALING necessary over 800℃
SEALING GLASS WITH LOW MELTING POINT necessary 400~550℃
PDMS HYBRID MATERIAL unnecessary 180〜250℃

DIRECT JOINING OF GLASS AND METAL

SELLING POINT

Direct joining is the technology that enables joining between glasses and metals without any adhesive material. This technology realizes high hermeticity (1×10-11Pa・m3/s or less) because the chemical reactions at the joining interface between glasses and metals by forming the oxide film make the so strong junction. Since the coefficient of thermal expansion of glasses and metals must be consistent when joining, the materials that can be combined are limited. Also, because the glasses need to be melted, the temperature at the time of joining is 800℃ or higher.

PRODUCT EXAMPLES

Medical electron tubes

Viewing ports, etc.

JOINING USING LOW MELTING POINT SEALING GLASS

SELLING POINT

Joining using low melting point sealing glass is a technology for joining glass to metal or glass to ceramics through low melting point glass. Since glass, metal, and ceramics react with low-melting glass, it is possible to achieve junction with excellent strength and hermeticity (1 x 10-9 Pa・m3/s or less). At the time of joining, it is necessary to melt the low melting point sealing glass, and heating at around 400 to 550℃ is required. Also, the coefficients of thermal expansion of glass, low melting point sealed glass, and metal or ceramics need to be consistent with each other, the combination materials are limited.

PRODUCT EXAMPLES

TO-Cap

Glass LID, etc.

JOINING USING HYBRID RESIN ADHESIVE

SELLING POINT

Joining with hybrid resin adhesive is the technology for joining using the original resin material named "hybrid material" developed by Nihon Yamamura Glass. The hybrid material is a silicone-based thermosetting resin whose main skeletal structure is Si-O bonds. Since the hybrid material has flexibility even after curing, it can join materials with significantly different coefficients of thermal expansion. In addition, since it maintains a certain level of hermeticity (around 1 x 10-8 Pa・m3/s), it can be used in applications that require not so high vacuum. Moreover, hybrid material has excellent UV resistance and is low in volatile components. In particular, the curing temperature is lower (180 to 250℃) than joining using sealing glass, so hybrid materials can be applied for devices with low heat resistance.

PRODUCT EXAMPLES

CaF2 Cap, etc.


03

SHEET FORMING

CERAMIC/GLASS GREEN SHEET

SELLING POINT

Yamamura Photonics has accumulated technologies of forming slurried glass powder, ceramics powder, and glass ceramics blended powder into sheets based on experience in manufacturing green sheets for LTCC substrates in the glass-ceramics business. We are also focusing on material design technology development, and we design the blended composition of glass and ceramics according to the substrate characteristics in addition to film formation technology. Furthermore, by developing the glass composition in collaboration with the parent company, Nihon Yamamura Glass New Glass Company, we strongly support the realization of the characteristics required by customers.

CUSTOMIZABLE ITEMS

Materials: Glass-ceramics, ceramics, and various glass powders
Sheet size: □100-500mm
Sheet thickness: 30-300 μm
Various physical characteristics: Please feel free to contact us

It is also possible to drill via holes in the sheet, to apply and fill various electrode pastes, and to make prototypes of laminated substrates.
If you provide us with images or drawings, we will consider the design and quotation.

FLOW FOR SHEETING

RESIN SHEET

SELLING POINT

Yamamura Photonics is developing technology for forming sheets of resin material named "hybrid material" developed by its parent company, Nihon Yamamura Glass New Glass Company. The hybrid material is a silicone-based thermosetting resin with Si-O bonds as the main chain and has high heat resistance up to 250℃ because it does not include C-C bonds in its structure. In addition, the volatilization of low-molecular-weight siloxane, which was a problem with conventional silicone-based materials, has been reduced to a very small amount by using particular raw materials. Also, the hybrid material has high UV resistance and excellent electrical insulation.
By taking advantage of these features, Yamamura Photonics is developing various sheets by combining our processing technology and the material development technology of New Glass Company. For example, optical clear adhesive (OCA) and thermal conductive sheet with high electrical insulation are included in these various sheets.

DEVELOPMENT EXAMPLE

OCA (Optical Clear Adhesive)

Thermal conductive sheet (insulation type)


04

ASSEMBLY

SELLING POINT

Yamamura Photonics has accumulated knowledge and technology in small parts assembly based on trial and mass production experience of small parts such as TO-Cap, glass LID, gas cell, and small airtight terminal. For example, for parts with a diameter of 5 mm or less, it is impossible to manufacture products with stable quality simply by reducing the size of large parts. At Yamamura Photonics, it is possible to manufacture glass-metal joint parts with a minimum size of about φ1 mm by designing the process in consideration of the problem of foreign matter generated due to miniaturization and the influence of the generation of air bubbles.

EXAMPLES OF PRODUCTS AND PROTOTYPES

Mini PKG (flat type)

Achieves the joining of small windows by an original process
Metal can shape: round, square
Window material size: around 2 square millimeters

Mini PKG (fused lens type)

Reduces diameter by directly joining the lens and metal can
Metal can shape: round
Lens diameter: φ1.6 mm ~

Side-sealed PKG

Achieves maximum inner height of windows by sealing the side of the window material with suppressing the PKG height.
Metal can shape: round
PKG size: φ5.6 mm ~
Window diameter: φ9-1.2 mm

In addition, we are particularly focusing on supporting the development phase of our customers, and we can handle even one custom design. If you want to assembly small parts, or if you are considering a custom design with a characteristic shape, please feel free to contact us.

05

OPTICAL DESIGN

OPTICAL COATING DESIGN

Optical devices have various applications, including sterilizations, lightings, images, optical communications, and sensors. Yamamura Photonics supports custom designs of optical coatings to propose the most suitable products for each application from ultraviolet to mid-infrared. After specifying the wavelength band to be used and the required transmittance or reflectance, we will design the optical coating and propose the simulation result of the transmittance or reflectance. In addition to anti-reflection (AR) coating in ultraviolet, visible light, and near-infrared, we can also propose various mirror coatings and bandpass filters. We can form an AR film on lenses, caps, and other specially shaped parts in addition to flat plates. And, we also support jig design for the coating process, so please feel free to contact us when considering custom coating design.

EXAMPLE OF OPTICAL COATING

Anti-reflective coat (AR)

Various mirrors

Various edge filters and bandpass filters, etc..

LENS DESIGN

Yamamura Kinik Optical (YKO) has become a member of the Yamamura group since 2018 so that the Yamamura Group is now able to design customized aspherical lenses.
YKO has many years of manufacturing experience in glass mold lenses and has accumulated design know-how. YKO can provide bare lenses, aspherical lens caps, aspherical lens holders, etc. In particular, YKO focuses on accepting inquiries for small quantities of custom prototypes and providing close support for customer development from the initial stage. Lens design, mold and glass preform design, and optical coating design are all carried out in-house, and the period from beginning to design to submission of prototype lens is about 1.5 to 2.5 months. YKO owns many molding machines and glass preform polishing machines. Also, YKO can handle mass production at its own factory.


06

QUALITY ASSURANCE

QUALITY ASSURANCE SYSTEM

Products of Yamamura Photonics are widely used not only in Japan but also around the world.
In response to daily inquiries from customers, such as requests for new products and quality improvement, we have built a system that enables each department to work closely together to respond to them speedily, and we are working to realize detailed support.

DESIGN DEVELOPMENT SYSTEM DIAGRAM

COMPLAINTS HANDLING SYSTEM DIAGRAM

TRACEABILITY

The production process history is essential information in dealing with quality problems and in daily quality improvement activities. Yamamura Photonics has built an original system that can trace from the receipt of parts to the shipment of products and is ready to retrieve the data accumulated for each process.

INSPECTION SYSTEM

Yamamura Photonics has an inspection system for each process to maintain product quality. Especially in the manufacturing process of small products such as optical parts, we have introduced multiple automatic inspection machines and inspected all products to guarantee their quality.


Automatic visual inspection machine (equipment developed in-house)

For products with metal cans with an outer diameter of up to φ9 mm stored in specially designated trays, we perform automatic 100% visual inspection according to the inspection standards (effective diameter, foreign matter, scratches, lens height, etc.) required by the customer.
We select the optimum lighting conditions and optical system for inspecting the products and make a pass or fail judgments by image processing.

Automatic leak inspection machine (equipment developed in-house)

We test products with an outer diameter of up to φ9 mm metal cans stored in specially designated trays for airtightness using automatic inspection equipment. The airtightness is judged by measuring the change in the degree of vacuum after sealing the inside of the products with negative pressure.

ANALYSIS SYSTEM

Yamamura Photonics owns various analysis devices for product performance evaluation.
In response to inquiries and requests from customers, the engineering department and the quality assurance department work together to analyze and investigate using analysis methods according to the content.

  • Observation of surface condition

    SEM/EDX

    Metallurgical microscope

    As the first step of investigation and analysis, we observe the appearance with SEM or metallurgical microscope, and we perform elemental analysis with EDX as needed.

  • Observation of cross section and inside

    Cross-section polishing equipment

    X-ray transmission device

    To observe the inside of a part, we use the X-ray transmission device with the sample kept in the original condition, or we observe the cross section by cutting and polishing the sample.

  • Environmental testing

    Temperature cycle testing machine

    High temperature and high humidity testing machine

    To evaluate the reliability of the products, we carry out durability tests and accelerated deterioration tests that apply temperature and humidity loads.

  • Product performance test

    He leakage detector

    Spectrophotometer

    X-ray fluorescence film thickness meter

    We have devices to measure airtightness and optical characteristics, which are the main performances of hermetic products.

  • Thermal characterization

    Thermomechanical analysis (TMA) equipment

    Differential thermal analysis (DTA) Equipment

    We have TMA, which measures the coefficient of expansion, and DTA, which analyzes changes in the sample due to temperature changes, as devices for measuring the thermal properties of glass and glass-ceramic sheets.

  • Particle size distribution measurement

    Particle size distribution measuring device

    The particle size distribution is measured to evaluate the characteristics of glass powder and ceramic powder.

  • Viscosity measurement

    Brookfield viscometer

    In the manufacturing process of glass-ceramic sheets, the viscosity of the slurry is controlled in order to maintain a constant film formation quality.

  • Strain stress measurement

    Polarimeter (strain measuring instrument)

    Microscopic distortion tester

    For large glass processed products, we supply highly reliable products by measuring the distortion of each product.

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