Eye-Tracking Glasses Lens Injection Molding Process
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Solution Overview
Problem
The existing process of setting photosensitive sensors on lenses for eye-tracking technology is time-consuming and difficult to control, leading to unstable yield due to multiple coating and drying processes required for encapsulation.
Innovation Solution
A method involving a substrate assembly with a functional film and pre-set electronic components, where an injection mold forms a lens with an optical adhesive encapsulating the components, simplifying the process and improving uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple coating and drying processes are used to encapsulate photosensitive sensors on lenses, then the encapsulation can be achieved, but the manufacturing time increases and the uniformity control becomes difficult
Solution Approach 1:
The patent combines multiple separate coating and drying processes into a single injection molding operation. The optical adhesive is injected in one step to encapsulate the photosensitive sensors, eliminating the need for sequential coating and drying steps. This merging of processes directly reduces manufacturing time while maintaining encapsulation uniformity through the controlled injection molding parameters.
Solution Approach 2:
The patent performs preliminary placement of the photosensitive sensors on the lens surface before the injection molding process. The sensors are positioned and secured on the substrate assembly prior to injecting the optical adhesive. This preliminary action ensures proper sensor positioning is achieved before encapsulation, allowing the single-step injection process to complete both positioning and encapsulation functions efficiently.
2Reliability
If multiple coating and drying processes are used to encapsulate photosensitive sensors on lenses, then the encapsulation can be achieved, but the process complexity increases and yield stability decreases
Solution Approach 1:
The patent merges multiple independent process steps (sensor placement, coating, drying, shaping) into a single integrated injection molding process. By combining these steps, the overall process complexity is reduced, making it easier to control and maintain consistent quality. The single-step process eliminates variability between separate operations, thereby improving yield stability.
Solution Approach 2:
The patent changes the physical state and processing parameters of the optical adhesive from a multi-step coating and drying process to a single injection molding process. The adhesive is injected in a liquid or semi-liquid state and cured in-situ, transforming the process from multiple discrete steps with varying parameters to a continuous single-step process with controlled injection pressure, temperature, and curing conditions. This parameter change simplifies process control and improves yield consistency.
3Strength
If photosensitive sensors are encapsulated on a substrate first and then adhered to the lens, then the sensors can be protected, but the manufacturing process becomes time-consuming and difficult to control
Solution Approach 1:
The patent performs preliminary placement and protection of the photosensitive sensors on the substrate assembly before the injection molding process. The sensors are positioned and secured on the substrate with preliminary protective measures in place. This preliminary action ensures sensor protection is achieved before encapsulation, allowing the subsequent injection molding to proceed as a single, easier-to-control step that provides additional encapsulation protection without requiring complex multi-step handling.
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 reduces manufacturing time and enhances the stability of the eye-tracking glasses by embedding electronic components within the lens using injection molding, ensuring efficient and uniform encapsulation.
Implementation Method 1
an injection mold is provided, a surface of the functional film with the electronic components arranged thereon faces an interior of an injection cavity, and liquid optical adhesive is injected into the injection cavity and shaped into a lens with the electronic components embedded in the lens
Data Source
AI summary
A method for preparing eye-tracking glasses, comprising the following steps: providing a substrate assembly, the substrate assembly comprising a functional film, the functional film being arranged on a surface of the substrate assembly, and electronic components being arranged on the surface of the functional film. Pressing an injection mold against the substrate assembly to form an injection cavity, and making the surface of the functional film with the electronic components face an interior of the injection cavity. Injecting and molding an optical adhesive in the injection cavity to form a lens, with the electronic components embedded in the lens. Demolding the injection mold from the lens, separating the functional film from the substrate assembly to obtain the eye-tracking glasses.