Electrostatic Lens Forming Device for Non-Spherical Surfaces
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Solution Overview
Problem
Existing methods for forming lenses, such as polishing and hybrid lenses, face challenges in producing non-spherical lenses with complicated shapes accurately and efficiently, leading to high production costs due to the need for multiple lenses to correct optical aberrations and difficulties in achieving high accuracy.
Innovation Solution
A lens forming device and method that utilize a dielectric body, a mold with a transfer surface, and an electric field to transfer and cure the dielectric body, generating an electrostatic attraction that shapes the lens accurately and reduces bubble formation, allowing for the creation of lenses with complicated shapes at lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polishing method is used to form lenses, then manufacturing process is established, but difficulty in forming non-spherical lenses and high production cost occur
Solution Approach 1:
The patent replaces the mechanical polishing system with an electrostatic-based forming system. A mold with the desired lens shape is pressed against a dielectric material under electrostatic attraction, transferring the lens shape directly without mechanical removal of material. This substitution enables efficient formation of non-spherical lenses while reducing production costs.
2Area of stationary object
If hybrid lens with thick resin layer is used to increase non-spherical surface area, then non-spherical surface area is increased, but number of lenses required increases and cost increases
Solution Approach 1:
The patent uses electrostatic pressing to directly form large-area non-spherical lenses in a single element, eliminating the need for hybrid lens constructions. The electrostatic field enables precise shape transfer to dielectric materials, allowing complex non-spherical surfaces to be formed cost-effectively without requiring multiple lens components.
3Device complexity
If pressing transfer surface to dielectric body without electric field, then transfer process is simple, but bubbles invade between transfer surface and dielectric body reducing accuracy
Solution Approach 1:
The patent introduces an electrostatic field between the mold and the dielectric material during the pressing process. This electrostatic attraction force pulls the dielectric material tightly against the transfer surface, preventing bubble formation and ensuring high-precision shape transfer. The addition of the electric field component resolves the accuracy issue while maintaining process simplicity.
4Manufacturing precision
If dielectric body is pressed to transfer surface, then lens shape is transferred, but dielectric body attaches to sides of mold requiring removal process
Solution Approach 1:
The patent applies local quality by creating non-uniform electrostatic attraction: the electric field strength is highest at the center of the mold, causing the dielectric material to be attracted primarily to the center region where the lens should form. This localized attraction prevents the material from adhering to the peripheral sides of the mold, eliminating the need for post-forming removal processes.
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 solution enables the formation of lenses with high accuracy and low cost, reducing the need for multiple lenses and minimizing bubble invasion, thus addressing the challenges of producing non-spherical lenses with large areas of non-spherical surfaces and complicated shapes.
Implementation Method 1
electric field generating means for generating an electric field between the mold and the substrate
Implementation Method 2
curing means for curing the dielectric body to which the transfer surface is pressed, so as to form a lens
Data Source
AI summary
In order to realize a device and a method each capable of forming a lens with high accuracy and low costs, a lens forming device of the present invention includes a metal mold, an insulating substrate, a stage, a power source, a switch, and a UV radiating device. Dielectric resin is supplied onto the insulating substrate and a transfer surface of the metal mold is pressed to the dielectric resin so as to transfer a lens shape to the dielectric resin. At that time, the power source applies a voltage on the metal mold to generate an electric field between the metal mold and the insulating substrate so that an electrostatic attraction causes the dielectric resin to be attracted toward the transfer surface of the metal mold while the top of the dielectric resin has a sharp cuspate shape. Consequently, bubbles are less likely to be invade between the transfer surface and the dielectric resin, allowing transferring a highly accurate lens shape to the dielectric resin.