Patterned Elastomeric Film for Curved Surface Patterning
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Solution Overview
Problem
Existing methods for forming patterns on curved surfaces, such as lenses, are time-consuming, expensive, and limited in their ability to produce high-volume, low-cost, flexible, and rapidly changeable micro- or nanostructures, particularly for concave, convex, and aspheric lenses.
Innovation Solution
The use of a patterned stretchable elastomeric film that conforms to the curved surface of a substrate, either bonding to the substrate with the pattern facing outward or using it as an imprint stamp with the pattern facing inward, to form precision patterns through radiation, thermal, or chemical imprinting, enabling the creation of refractive or diffractive optical elements and metal or dielectric patterns for enhanced performance and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional methods like laser interferometry are used to form patterns on curved surfaces, then pattern formation is achieved, but the process becomes time-consuming and expensive
Solution Approach 1:
The patent uses a master patterned stamp to create replicas of optical patterns on curved surfaces. The stamp is pressed against the substrate to transfer the pattern, enabling rapid replication without time-consuming interferometry calculations or iterative adjustments, thus maintaining precision while dramatically reducing formation time
Solution Approach 2:
The patent replaces the complex optical-mechanical interferometry system with a direct mechanical stamping process. Instead of using laser beams and interference patterns to define features, a physical stamp with pre-formed patterns is pressed onto the substrate, substituting a simple mechanical transfer for a complex optical measurement and fabrication system
2Manufacturing precision
If conventional patterning methods are used on curved surfaces, then patterns can be formed, but the process is not adaptable to different curvatures and patterns
Solution Approach 1:
The patent employs a compliant stamp material that can dynamically adapt its shape to match different substrate curvatures. The stamp is not rigid but flexible enough to conform to various curved surfaces while maintaining pattern fidelity, enabling the same stamping process to be used across multiple curvature radii and pattern types without requiring dedicated tools for each configuration
Solution Approach 2:
The patent creates a universal stamping system where a single stamping apparatus can produce multiple different optical patterns on various curved substrates. By changing the stamp design or the substrate, the same basic process can generate diffractive patterns, refractive patterns, or combined patterns on lenses of different curvatures, making the system highly versatile
3Manufacturing precision
If traditional patterning approaches are used, then patterns can be formed on curved surfaces, but high-volume low-cost production is not achieved
Solution Approach 1:
The patent enables high-volume production through rapid pattern replication using stamps that can be repeatedly pressed onto substrates. Each stamping cycle quickly transfers the pattern without requiring time-consuming processing steps, allowing thousands of lenses to be patterned efficiently while maintaining consistent quality across all replicas
Solution Approach 2:
The patent utilizes relatively simple, inexpensive stamps that can be manufactured at low cost. These stamps, while potentially having limited lifetimes compared to expensive precision instruments, provide a cost-effective solution for high-volume production where the low per-unit tooling cost combined with rapid cycling achieves superior overall economics
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 method allows for rapid, low-cost formation of precision patterns on curved surfaces, improving optical performance, enabling the integration of anti-reflection structures, aberration correction, light control, and electrical circuitry, while being adaptable for various curvatures and patterns, facilitating high-volume production.
Implementation Method 1
a patterned stretchable elastomeric film that conforms to the curved surface of a substrate
Implementation Method 2
radiation, thermal or chemical imprinting
Implementation Method 3
radiation, thermal or chemical imprinting
Data Source
AI summary
Methods are disclosed by which two-dimensional and three-dimensional pattern layers may be formed on non-planar surfaces, including optical elements such as lenses with one or more cylindrical, spherical or aspheric surfaces. Patterns with features in the micro- and/or nano-size regime comprised of organic, inorganic or metallic materials may be formed by the methods described herein.