Optical Substrate with Embedded Low-Refractive Particles

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Solution Overview

Problem

Existing optical articles, particularly ophthalmic lenses, face challenges in achieving high light transmission without the need for antireflective surface coatings, especially for high refractive index materials, which are costly and complex to manufacture, and often result in cosmetic defects and reduced mechanical properties.

Innovation Solution

Embedding particles with a lower refractive index than the polymer matrix into the substrate's external layer during the manufacturing process, using a method that integrates particle application onto the mold surface before casting or injection molding, to enhance light transmission and reduce reflection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If antireflective surface coatings are applied to high refractive index materials, then light transmission is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvelight transmissionVSAvoidmanufacturing complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent combines the substrate material and antireflective particles into a single integrated component. Particles are embedded directly into the polymer matrix during molding, eliminating the need for separate coating layers and their associated manufacturing steps (surface pretreatment, coating application, curing). This merging resolves the contradiction by achieving light transmission enhancement without increasing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a composite material system where antireflective particles are dispersed within the polymer matrix. This composite approach allows the substrate itself to possess antireflective properties, eliminating the need for separate coating materials and processes. The composite structure resolves the contradiction by integrating multiple functions into a single material system.

Inventive Principle:

Principle #40Composite materials

2Illumination intensity

If antireflective surface coatings are applied, then light transmission is improved, but production time increases

Engineering Contradiction:

Improvelight transmissionVSAvoidproduction time

Core Design Contradiction:

Illumination intensityVSProductivity

Solution Approach 1:

The patent performs the antireflective function during the initial molding process rather than as a subsequent step. Particles are incorporated into the polymer matrix before the substrate is formed, or embedded during the molding process itself. This preliminary action eliminates the need for separate coating application and curing steps, thereby reducing production time while maintaining light transmission enhancement.

Inventive Principle:

Principle #10Preliminary action

3Illumination intensity

If surface coatings are used to improve light transmission, then optical properties are enhanced, but mechanical properties deteriorate

Engineering Contradiction:

Improvelight transmissionVSAvoidmechanical properties

Core Design Contradiction:

Illumination intensityVSStrength

Solution Approach 1:

The patent merges the structural substrate and functional coating into a single integrated component. By embedding particles within the polymer matrix, the substrate itself provides both mechanical strength and antireflective properties. This eliminates the interface between substrate and coating that would be prone to delamination, thereby maintaining mechanical integrity while achieving optical enhancement.

Inventive Principle:

Principle #5Merging (Combining)

4Illumination intensity

If particles are embedded into the substrate, then light transmission is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvelight transmissionVSAvoidmanufacturing simplicity

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent combines particle embedding with the standard injection molding process. The polymer matrix is injected onto a mold surface that has been prepared with particles, and the particles become embedded during the normal molding cycle. This integration means that while particle preparation is an additional step, the actual embedding requires no special equipment or complex processes beyond standard molding operations.

Inventive Principle:

Principle #5Merging (Combining)

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 approach increases light transmission in the visible spectrum while maintaining mechanical properties and reducing manufacturing complexity, resulting in cost-effective, uncoated lenses with improved optical clarity and cosmetic appearance.

Implementation Method 1

the refractive index of the particles Rp being lower than the refractive index of the polymer matrix Rs

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

Decreasing the reflection at both main surfaces of a material results in an increased transmission through said material

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentEP3665514B1Optical article comprising a substrate with embedded particles for light transmission enhancement

Publication Date: 2024.10.02 ESSILOR INTERNATIONAL(COMPAGNIE GENERALE D OPTIQUE)

Figure 1~3

AI summary

The invention relates to an optical article having a substrate made of an optical material comprising a polymer matrix and an improved light transmission in the visible range. The substrate comprises an external layer in which particles are embedded into the polymer matrix, the refractive index of the particles Rp being lower than the refractive index of the polymer matrix Rs.