Aspheric Lens with Viscous Fluid Core and Pressure Capsule
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical lens production methods are inefficient and costly, particularly due to manual grinding and polishing of solid optical materials, which can result in significant waste if errors occur during the process.
Innovation Solution
The development of an optical lens comprising an aspheric-shaped shell and an optical plate with a viscous fluid sealed between them, where a capsule is used to maintain constant pressure within the cavity over a range of operating temperatures, allowing for efficient production and minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual grinding and polishing of solid optical materials is used, then manufacturing precision can be achieved, but productivity is low and material waste is high
Solution Approach 1:
The patent uses a viscous fluid instead of manual mechanical grinding and polishing. The fluid is pressed against the mold cavity to form the lens surface, eliminating manual labor and significantly improving productivity while maintaining precision through controlled fluid pressure and mold design.
Solution Approach 2:
The invention changes the state of the optical material from solid to liquid/viscous form. By controlling the viscosity and pressure parameters of the fluid, the lens can be formed efficiently without manual grinding, resolving the contradiction between precision and productivity.
2Manufacturing precision
If manual grinding and polishing of solid optical materials is used, then manufacturing precision can be achieved, but material waste increases due to errors
Solution Approach 1:
The viscous fluid method allows for easier correction of errors during the forming process. If a mistake occurs, the fluid can be repressed or adjusted without requiring removal and replacement of the entire lens, thereby reducing material waste compared to solid material processing.
Solution Approach 2:
The liquid/viscous state of the optical material allows for flexible adjustment and correction during manufacturing. Errors can be remedied by changing pressure or flow parameters, preventing total material loss that occurs with solid material grinding and polishing.
3Productivity
If viscous fluid is used in the cavity, then productivity improves and material waste reduces, but pressure control becomes critical for maintaining optical properties
Solution Approach 1:
The capsule filled with compressible gas or liquid automatically compensates for pressure changes due to temperature variations. The capsule expands or contracts as needed, maintaining constant pressure on the viscous fluid without requiring an external pressure control system, thus simplifying the device while ensuring optical property stability.
Solution Approach 2:
The capsule utilizes phase transitions or compressibility of the gas/liquid inside to automatically regulate pressure. When temperature changes cause volume expansion or contraction of the capsule contents, the pressure on the viscous fluid remains constant, eliminating the need for complex active pressure control mechanisms.
4Ease of manufacture
If solid optical materials are processed, then traditional manufacturing methods can be used, but the process is costly and time-consuming
Solution Approach 1:
The viscous fluid is injected into the mold cavity and rapidly formed into the lens shape through pressure application. This hydraulic forming process is much faster than traditional solid material grinding and polishing, significantly reducing production cycle time while maintaining manufacturing simplicity through automated fluid injection and molding.
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
This solution enables cost-effective and efficient production of optical lenses by reducing material waste and maintaining optical properties through temperature-controlled pressure management, enhancing manufacturing efficiency and reducing the reliance on manual processing of solid materials.
Implementation Method 1
the capsule is configured to transport the viscous fluid into and out of the cavity based upon a temperature change of the optical lens
Implementation Method 2
the capsule is configured to maintain a substantially constant pressure within the cavity over a range of operating temperatures of the optical lens
Data Source
AI summary
An optical lens includes an aspheric-shaped shell formed of an optical material, an optical plate connected to the aspheric-shaped shell, and a viscous fluid fluidically sealed in a cavity between the aspheric-shaped shell and the optical plate.