GRIN Lens Sol-Gel Manufacturing with Boron Alkoxide Leaching
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Solution Overview
Problem
The existing sol-gel method for manufacturing GRIN lenses faces challenges in controlling bulk density while maintaining a desired refractive-index distribution, often resulting in foaming and cracking during sintering and drawing, which affects yield and requires skilled operators due to high viscosity and reactivity of aluminum alkoxide.
Innovation Solution
A method using an alcohol solution with silicon alkoxide, dopant alkoxide, and boron alkoxide as main ingredients, where boron is added and stirred for 10-150 minutes, then leached to achieve a refractive index distribution, resulting in a dry gel with low boron concentration (<0.1 mol%) to enhance porosity and prevent foaming, allowing for stable and high-yield production even by non-skilled operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If aluminum alkoxide is used to control bulk density during leaching, then refractive index distribution is improved, but bulk density becomes high causing foaming and cracking during sintering
Solution Approach 1:
The patent changes the chemical composition parameter by substituting aluminum alkoxide with boron alkoxide. This parameter change allows the leaching process to create pores without leaving residual metal that would cause foaming during sintering, thus resolving the contradiction between achieving refractive index distribution and preventing harmful foaming
Solution Approach 2:
Boron acts as a temporary sacrificial component during the leaching process. It is intentionally added to create pore structure, then completely removed through leaching, leaving behind only the desired porous structure without harmful residuals. This disposable approach eliminates the foaming problem while maintaining the refractive index distribution benefit
2Manufacturing precision
If aluminum alkoxide is used in the sol-gel process, then bulk density control is improved, but ease of operation deteriorates due to high viscosity and reactivity
Solution Approach 1:
The patent changes the physical and chemical parameters of the alkoxide component from aluminum to boron. Boron alkoxide has lower viscosity and moderated reactivity compared to aluminum alkoxide, making the sol-gel process easier to handle and mix while still achieving the desired bulk density control through the leaching process
3Manufacturing precision
If leaching is performed to create concentration distribution, then refractive index distribution is improved, but bulk density becomes high reducing porosity
Solution Approach 1:
The patent changes the leaching mechanism by using boron instead of aluminum. The boron leaching process is more effective at creating pores while maintaining concentration distribution, as boron can be completely removed without leaving residuals that would fill the pores, thus achieving both concentration distribution and high porosity simultaneously
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 method achieves high porosity in dry gels, preventing cracking and foaming during sintering and drawing, leading to improved yield and stability in GRIN lens production with reduced boron oxide content, ensuring efficient refractive index distribution and manufacturing process.
Implementation Method 1
boron is added and stirred for 10-150 minutes
Implementation Method 2
eluting the dopant and the boron from the outer surface of the wet gel by leaching to give a refractive index distribution
Implementation Method 3
drying the wet gel to produce a dry gel
Implementation Method 4
sintering the dry gel to form a glass base material
Implementation Method 5
drawing the base material
Data Source
AI summary
[Object] In manufacturing a GRIN lens by a sol-gel method, an operation for preparing a wet gel is facilitated and cracking in a base material during sintering and foaming during drawing are prevented. [Solution] The object is achieved by obtaining a GRIN lens by producing a wet gel from an alcohol solution containing a silicon alkoxide, a dopant alkoxide, and a boron alkoxide as the main ingredients, leaching the same, drying the same to form a dry gel, and sintering and drawing the same.