Hybrid Lens Adhesion and Light-Shielding Precision
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Solution Overview
Problem
Hybrid lenses with glass and resin laminated together face issues of peeling and shifting due to low adhesiveness, especially when exposed to high temperatures, and struggle with precision in manufacturing, particularly with the light-shielding portion, leading to inconsistent quality and precision problems.
Innovation Solution
A hybrid lens design featuring a glass substrate, a resin lens, and an adhesive layer with a specific glass transition temperature difference between the resin and the adhesive, along with a metal compound layer for precise lamination, and the use of particles or butting parts in the adhesive layer for uniform clearance, ensures strong adhesion and precision in manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If glass and resin lenses are laminated together to create a hybrid lens, then the optical characteristics of both materials are utilized, but peeling and shifting occur due to low adhesiveness
Solution Approach 1:
An adhesive layer is introduced as an intermediary between the glass substrate and the resin lens. This adhesive layer specifically addresses the adhesion problem by providing a bonding interface that overcomes the inherent low adhesiveness between glass and resin materials, preventing peeling and shifting while allowing both materials to maintain their optical characteristics.
Solution Approach 2:
The hybrid lens employs a composite structure combining glass substrate, adhesive layer, and resin lens. This composite material approach leverages the advantages of each material - the optical properties of glass and resin - while the adhesive layer ensures reliable bonding between them, creating a functional composite system that overcomes the weakness of individual material combinations.
2Object-affected harmful factors
If black stainless steel is used as the light-shielding portion, then light blocking is achieved, but dicing precision deteriorates and manufacturing difficulty increases
Solution Approach 1:
The light-shielding function is extracted from the black stainless steel and transferred to a chromium oxide layer formed by vapor deposition. This extraction allows the dicing process to be performed on the glass substrate without the interference of the black stainless steel, improving dicing precision while maintaining effective light blocking through the chromium oxide layer.
Solution Approach 2:
The mechanical dicing process is improved by replacing the black stainless steel light-shielding layer with a chromium oxide layer that is more suitable for precise dicing. The chromium oxide layer provides comparable light blocking properties but with better mechanical characteristics for the dicing operation, reducing manufacturing difficulty.
3Object-affected harmful factors
If black resist is used as the light-shielding portion, then light blocking is achieved, but etching precision deteriorates and the black resist peels from the glass
Solution Approach 1:
The chromium oxide layer formed by vapor deposition serves as an intermediary that replaces the black resist for light-shielding purposes. This intermediary layer provides superior etching precision and adhesion to the glass substrate compared to black resist, while maintaining the light blocking function. The vapor deposition process ensures precise formation without peeling issues.
4Temperature
If the hybrid lens is exposed to high temperature environment, then thermal expansion occurs, but floating and peeling occur due to large difference in linear expansion coefficients
Solution Approach 1:
The adhesive layer acts as a mediator between the glass substrate and resin lens, specifically addressing the thermal expansion mismatch problem. By selecting an adhesive material with appropriate thermal expansion properties, the layer compensates for the large difference in linear expansion coefficients between glass and resin, preventing floating and peeling in high temperature environments.
Solution Approach 2:
The selection of adhesive material with specific thermal and mechanical parameters is critical. By changing the parameters of the adhesive layer - such as its elastic modulus, thermal expansion coefficient, and glass transition temperature - the system can accommodate the thermal expansion differences between glass and resin, maintaining reliable bonding under thermal stress.
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 solution prevents peeling and shifting of the glass and resin lenses at high temperatures, maintains precision in the light-shielding portion, and ensures uniform clearance between the glass and resin lenses, resulting in a stable and accurately manufactured hybrid lens.
Implementation Method 1
an adhesive layer provided between the glass substrate and the resin lens
Implementation Method 2
as an optical diaphragm (light-shielding portion), electrolytically oxidized black stainless steel or a black resist is generally formed
Implementation Method 3
a chromium oxide layer formed by vapor deposition is used as the light-shielding portion
Implementation Method 4
the resin is applied to the surface of the glass, the resin is cured while being pressed with a mold
Data Source
AI summary
As a first aspect, provided is a hybrid lens for which peeling and shifting of a glass and a resin lens do not easily occur, and for which floating of an adhesive layer and peeling between the glass and resin lens do not easily occur even when the hybrid lens is exposed to a high temperature environment. As a second aspect, provided is an easily produced hybrid lens in which a glass and a resin lens are laminated, and in which the resin lens and a light-shielding portion are laminated with good precision.The hybrid lenses 11 and 12 each include a glass substrate 3, a resin lens 2, and an adhesive layer 4 provided between the glass substrate 3 and the resin lens 2. In the hybrid lens 11, the glass transition temperature of the resin lens 2 is higher than the glass transition temperature of the adhesive layer 4, and the difference between the glass transition temperature of the resin lens 2 and the glass transition temperature of the adhesive layer 4 is from 97 to 150° C. The hybrid lens 12 further includes a metal compound layer 52 provided between the glass substrate 3 and the resin lens 2.