Composite Polarized Lens with Volumetric Light Absorbers
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Solution Overview
Problem
Conventional methods for producing polarized eyeglasses lenses face issues with inadequate infrared absorbing performance, inefficient use of functional agents, and poor adhesive integration between lens substrates, leading to increased manufacturing costs and optical defects like light shadows due to differences in resin types and heat histories.
Innovation Solution
A composite functional polarized lens is created by integrally forming lens substrate layers on both surfaces of a polarizing film using insert molding, where one surface contains a light absorber and the other does not, ensuring good adhesive properties and efficient use of functional agents like ultraviolet, infrared, and photochromic absorbers, regardless of resin type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a coating layer containing infrared absorber is applied on the lens surface, then infrared absorbing performance is improved, but the thickness of the coating layer must be kept thin to maintain optical characteristics, resulting in insufficient infrared absorption
Solution Approach 1:
The patent transitions from a two-dimensional surface coating approach to a three-dimensional volumetric distribution by incorporating the infrared absorber throughout the lens substrate thickness. This allows sufficient infrared absorption without requiring a thick surface coating that would compromise optical characteristics.
Solution Approach 2:
The patent applies different functional properties to different regions of the lens substrate. The infrared absorber is distributed specifically within the lens substrate material, creating local functional zones that provide infrared absorption while maintaining the overall optical quality of the lens.
2Object-affected harmful factors
If a costly function-imparting agent such as ultraviolet ray absorber or infrared absorber is dispersed and retained on a lens substrate for visual correction, then the functional performance is improved, but a grinding operation removes the most part of the lens substrate, causing the function-imparting agent to be wasted without performing its function
Solution Approach 1:
The patent incorporates the function-imparting agent into the lens substrate material before the grinding operation. By pre-distributing the infrared or ultraviolet absorber throughout the lens substrate, the functional agent remains in the final ground lens, ensuring it performs its intended function rather than being removed with the ground material.
Solution Approach 2:
The patent creates a composite lens substrate by combining the base lens material with function-imparting agents (infrared absorbers, ultraviolet absorbers). This composite structure ensures the functional agents are integrated into the lens matrix, so they remain after grinding and continue to provide their protective functions.
3Object-affected harmful factors
If a polarizing element is formed by coating both surfaces of a polarizing film with a polyurethane resin containing an infrared absorber and a lens substrate for eyeglasses is formed with a polyurethane resin which does not contain an infrared absorber, then infrared absorbing function is achieved, but the adhesive integration between the polarizing element and lens substrate is poor
Solution Approach 1:
The patent uses the same polyurethane resin for both the polarizing element coating and the lens substrate formation. This homogeneity in resin type ensures compatible adhesive properties and thermal characteristics, allowing the polarizing element to be firmly integrated with the lens substrate without delamination issues.
Solution Approach 2:
The patent modifies the resin composition parameter by incorporating the infrared absorber into the polyurethane resin itself, rather than using different resin types. This parameter change maintains resin compatibility while achieving the infrared absorption function, resolving the conflict between functionality and adhesive integration.
4Ease of manufacture
If the resin layer is formed in advance on one surface of the polarizing element and a second resin layer is additionally formed on the resin layer during insert molding, then the lens structure is created, but an optically distinguishable interface is formed due to difference in flow direction of the resins and heat history, causing light shadows
Solution Approach 1:
The patent combines the formation of the polarizing element and lens substrate into a single integrated molding process. By molding both components simultaneously from the same polyurethane resin, the patent eliminates the interface between separately formed resin layers, thereby preventing light shadows and maintaining optical quality.
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 configuration ensures excellent adhesive integration without optical defects, efficient use of functional agents, and maintains optical quality by preventing light shadows, even with challenging resin types like diethyleneglycol-bis-allylcarbonate, while reducing manufacturing costs.
Implementation Method 1
a polarizing element having a polarizing membrane (film)
Implementation Method 2
one surface contains a light absorber and the other does not... efficient use of functional agents like ultraviolet, infrared, and photochromic absorbers
Implementation Method 3
efficient use of functional agents like ultraviolet, infrared, and photochromic absorbers
Data Source
AI summary
A composite functional polarized lens is a polarized lens in which lens substrate layers made of, for example, an allyl diglycol carbonate resin (produced by PPG Industries: CR-39), an urethane resin or other predetermined resin are integrally formed on both front and back surfaces of a polarizing film by way of insert molding, wherein a first lens substrate layer formed on the front surface of both the front and back surfaces of the polarizing film contains a light absorber which is an ultraviolet absorber, an infrared absorber, photochromic light absorber or a thermochromic light absorber as an additional component, and a second lens substrate layer formed on the back surface does not contain the light absorber.