Curable Lens Composition Mold Transfer Accuracy
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Solution Overview
Problem
The production of lenses for electronic devices faces challenges with 'bubble entrapment' during the molding process, which affects transfer accuracy, and existing materials lack optimal heat resistance and optical properties.
Innovation Solution
A curable composition comprising a cycloaliphatic epoxide, a cationic-polymerization initiator, and a polysiloxane, with specific formulations to enhance wettability and minimize bubble entrapment, while providing excellent heat resistance and optical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a curable composition containing a cationically curable compound is used to produce reduced-size lenses using a mold, then lens miniaturization is achieved, but bubble entrapment occurs during charging which impairs transfer accuracy from the mold
Solution Approach 1:
The invention changes the chemical composition parameters of the curable composition by adding specific polysiloxanes with controlled molecular weights and structures. This modifies the physical properties (viscosity, surface tension) of the composition to improve mold charging behavior and eliminate bubble entrapment while maintaining the ability to produce miniaturized lenses with high transfer accuracy
Solution Approach 2:
The invention creates a composite curable composition by combining cationically curable compounds with specific polysiloxanes. This composite material leverages the heat resistance and optical properties of the cationically curable compound while the polysiloxane component improves wettability and reduces bubble formation during mold charging, achieving both miniaturization and high manufacturing precision
2Ease of manufacture
If thermoplastic resins are used for lens formation, then the production process is simplified, but the lenses lack reflow heat resistance
Solution Approach 1:
The curable composition combines cationically curable compounds (providing heat resistance) with polysiloxanes (improving processing characteristics). This composite material achieves both reflow heat resistance and ease of manufacture through mold-based formation processes, resolving the contradiction between material performance and manufacturing simplicity
3Temperature
If acrylic resins or silicone resins are used for lens formation, then heat resistance is improved, but optical properties are not satisfactory
Solution Approach 1:
The invention creates a composite curable composition where cationically curable compounds provide the base resin matrix with good optical properties, while added polysiloxanes enhance heat resistance. The synergistic combination achieves both satisfactory optical properties and improved heat resistance that neither material alone could provide
Solution Approach 2:
The polysiloxane components are incorporated at specific concentrations (0.01-5% by weight) to locally enhance heat resistance properties without compromising the overall optical quality of the lens. This controlled local modification allows optimization of both heat resistance and optical properties
4Manufacturing precision
If the polysiloxane content is increased to improve wettability and reduce bubble entrapment, then transfer accuracy improves, but the curability and optical properties may be compromised
Solution Approach 1:
The invention optimizes the polysiloxane content within a specific range (0.01-5% by weight) to achieve the desired balance. This parameter optimization ensures sufficient wettability improvement and bubble entrapment reduction while maintaining adequate curability and optical properties of the final lens product
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
The composition achieves improved transfer accuracy and maintains high heat resistance and optical quality, suitable for producing lenses with reduced size, weight, and thickness, such as wafer-level and Fresnel lenses.
Implementation Method 1
a cationic-polymerization initiator (B)
Implementation Method 2
the curable composition including a specific epoxide and a specific polysiloxane can have better wettability with a mold, and this eliminates or minimizes the occurrence of 'bubble entrapment' upon charging of the curable composition into the mold
Data Source
Figure 1(a)~1(b)
AI summary
Provided is a curable composition capable of giving a lens that has excellent transfer accuracy from a mold and offers heat resistance and optical properties at excellent levels. The curable composition according to the present invention for lens formation contains a cycloaliphatic epoxide (A) represented by Formula (a), a cationic-polymerization initiator (B), and a polysiloxane (C) represented by Formula (c). The curable composition contains the polysiloxane (C) in an amount of 0.01% to 5% by weight based on the total amount of the curable composition. The curable composition according to the present invention for lens formation may further contain a siloxane compound (D) containing two or more epoxy groups per molecule.