Epoxy Lens Anti-Reflection Layer for Reflow Crack Resistance
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Solution Overview
Problem
Conventional anti-reflection coatings on epoxy lenses fail due to mismatch in thermal expansion coefficients, leading to stress-induced wrinkles and cracks during reflow processes, and existing methods for forming nanostructures on non-etchable epoxy materials are limited.
Innovation Solution
Form anti-reflection structures in an additional layer of high-etchability epoxy material conformally deposited on the lens surface, decoupling the anti-reflection capabilities from the lens properties to ensure robustness and desired optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional anti-reflection coatings are applied on epoxy lenses, then light transmission is improved, but thermal expansion mismatch causes stress-induced wrinkles and cracks during reflow processes
Solution Approach 1:
The patent divides the anti-reflection function from the lens substrate by adding a separate epoxy layer on top of the lens. This additional layer is specifically designed to receive anti-reflection structures while the lens maintains its original optical properties. The segmentation allows the anti-reflection coating to be optimized independently from the lens material, preventing thermal expansion mismatch issues.
Solution Approach 2:
The patent introduces an intermediary epoxy layer between the lens and the anti-reflection structures. This intermediary layer acts as a buffer that decouples the thermal expansion coefficients of the lens and the coating, preventing stress transfer that would cause wrinkles and cracks during reflow processes.
2Loss of energy
If anti-reflection structures are formed directly on epoxy lens surface, then optical performance is improved, but the non-etchable nature of epoxy limits structure formation precision
Solution Approach 1:
The patent applies a preliminary action by depositing an additional epoxy layer on the lens surface before forming the anti-reflection structures. This pre-prepared layer provides a suitable substrate with appropriate etchability, enabling precise structure formation while the lens itself remains unchanged.
Solution Approach 2:
The patent changes the material parameter of the surface layer by adding an epoxy coating with different etchability properties compared to the lens material. This parameter change enables the formation of precise anti-reflection structures on the surface without affecting the bulk lens properties.
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 additional layer allows for the formation of anti-reflection structures with desired height and geometry, maintaining optical performance and reliability even after reflow processes, enhancing light transmission and reducing glare.
Implementation Method 1
an additional layer of high-etchability epoxy material conformally deposited on the lens surface
Implementation Method 2
anti-reflection structures with desired height and geometry, maintaining optical performance and reliability even after reflow processes, enhancing light transmission and reducing glare
Data Source
AI summary
The present disclosure relates to an optical element (200) comprising: a lens element (202) configured to implement a lens function, wherein the lens element (202) comprises an epoxy material; and an additional epoxy layer (204) disposed on an optical surface (208) of the lens element (202), wherein the additional epoxy layer (204) includes anti-reflection structures (206) formed in the additional epoxy layer (204).