Embossed Film Encapsulation for Protected Microlens Geometry
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Solution Overview
Problem
Conventional optical coatings on lenses do not provide adequate protection for optical elements such as microlenses, which can be susceptible to damage and alter the optical design, leading to a need for improved protection without altering the optical properties.
Innovation Solution
An embossed film with encapsulating optical layers that protect concave and convex microlenses, using primary and secondary optical layers to fully encapsulate these elements, maintaining their optical design and providing enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coatings (hard coat or varnish) are applied to optical elements, then some protection is provided, but the geometric shape and optical design of the optical elements are altered
Solution Approach 1:
The patent applies a protective coating that is embossed to form a nested structure where the coating itself creates recessed areas that accommodate the optical elements. This nesting approach allows the protective layer to envelop the optical elements while maintaining their original geometric shape and optical properties, as the coating conforms to the element geometry rather than imposing a different shape.
Solution Approach 2:
The patent changes the physical parameters of the protective coating by embossing it to create a three-dimensional structure with varying thickness and depth. This parameter change allows the coating to provide enhanced protection through its embossed geometry while maintaining optical neutrality, as the embossed structure does not alter the refractive properties of the underlying optical elements.
2Reliability
If conventional coatings are applied to optical elements, then some protection is provided, but the optical performance is compromised due to alteration of optical design
Solution Approach 1:
The embossed protective coating creates a nested configuration where the coating structure adapts to the optical element geometry. This ensures that the protective function is achieved without compromising the optical design precision, as the coating follows the contours of the elements rather than distorting them.
Solution Approach 2:
The embossed coating creates a geometric copy or replica of the optical element surface profile. By copying the surface geometry, the coating provides protection while maintaining optical neutrality, as the copied geometry does not introduce new optical characteristics that would alter the designed optical performance.
3Shape
If optical elements are exposed without adequate protection, then their optical design is maintained, but they are susceptible to damage
Solution Approach 1:
The patent employs a flexible embossed coating that acts as a protective shell or thin film over the optical elements. This flexible coating provides mechanical protection against damage while maintaining the optical design integrity, as the thin film structure does not significantly alter the optical properties of the underlying elements.
Solution Approach 2:
The embossed coating structure provides beforehand cushioning by creating a protective layer with embossed features that can absorb or distribute mechanical stresses before they reach the optical elements. This prior cushioning protects against damage while maintaining optical performance.
Data Source
AI summary
The present disclosure includes optical articles comprising a film layer that has first and second film surfaces and is embossed such that the first film surface defines a plurality of concave optical elements and the second film surface defines a plurality of convex optical elements. The present optical articles can include one or more optical layers coupled to the film layer. Each of the optical layer(s) can encapsulate the concave optical elements or the convex optical elements.