Laminated Diffractive Optical Element Polymer Control
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Solution Overview
Problem
The existing laminated diffractive optical elements with transparent conductive particles suffer from appearance malfunctions due to the generation of polymers during the manufacturing process, leading to increased cloudiness when intense light is applied, primarily because the transparent conductive particles act as catalysts in the polymerization reaction before the energy curable resin is fully cured.
Innovation Solution
The solution involves controlling the oxygen partial pressure during the solvent elimination process from the energy curable resin raw material and transparent conductive particles mixture, ensuring that the solvent is eliminated under reduced pressure and atmospheric air opening, which suppresses the polymerization reaction and maintains a polymer ratio of 70 pieces/mm3 or less in the first resin layer, thereby preventing the appearance malfunction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transparent conductive particles are added to the energy curable resin to improve electrical conductivity and optical properties, then the diffraction efficiency is enhanced, but polymerization reactions occur before curing due to catalyst action of the particles, generating polymers that cause appearance malfunctions and cloudiness
Solution Approach 1:
The patent applies preliminary action by eliminating the solvent from the energy curable resin and transparent conductive particles mixture before the polymerization reaction can occur. This is achieved through reduced pressure treatment and atmospheric air opening that removes the solvent in advance, preventing the catalyst-induced polymerization that would otherwise generate harmful polymers and cloudiness in the final product.
Solution Approach 2:
The patent creates an inert environment by controlling the atmospheric conditions during solvent elimination. By using reduced pressure and controlled atmospheric air opening, the process prevents unwanted chemical reactions (polymerization) that would occur in normal atmospheric conditions, thereby maintaining the stability of the transparent conductive particles and preventing harmful polymer generation.
2Manufacturing precision
If the solvent is eliminated from the energy curable resin raw material and transparent conductive particles mixture, then the polymerization reaction is suppressed and appearance quality is improved, but the manufacturing process complexity increases due to controlled pressure and atmospheric conditions
Solution Approach 1:
The patent applies parameter changes by systematically controlling pressure conditions during solvent elimination. The process involves specific reduced pressure levels and controlled atmospheric air opening sequences, which change the physical parameters of the manufacturing environment to suppress polymerization reactions and prevent appearance malfunctions while maintaining manufacturing feasibility.
3Manufacturing precision
If the polymer ratio is maintained at 70 pieces/mm3 or less through controlled solvent elimination, then the appearance malfunction is prevented, but the manufacturing time increases due to the controlled pressure and atmospheric air opening process
Solution Approach 1:
The patent performs solvent elimination as a preliminary action before the polymerization reaction occurs. By removing the solvent in advance under controlled pressure conditions, the process prevents polymer generation at its source, ensuring the polymer ratio remains at 70 pieces/mm3 or less without requiring additional post-processing steps, thereby minimizing time loss.
Solution Approach 2:
The controlled atmospheric environment during solvent elimination creates conditions that suppress polymerization reactions. By maintaining this inert atmosphere throughout the solvent removal process, the patent prevents harmful polymer formation without requiring extended processing times or additional corrective measures, thus balancing manufacturing precision with time efficiency.
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 approach results in a laminated diffractive optical element with excellent appearance quality, achieving diffraction efficiency of 99.5% or more in the whole visible region without any cloudiness when intense light is applied, as demonstrated in the examples.
Implementation Method 1
the transparent conductive particles act as catalysts in the polymerization reaction before the energy curable resin is fully cured
Implementation Method 2
a polymerization reaction occurred before the energy curable resin was cured by applying energy
Data Source
AI summary
A laminated diffractive optical element includes a first resin layer having a first lattice shape and a second resin layer having a second lattice shape. The first resin layer and the second resin layer are laminated in this order on a first substrate so that the lattice shapes oppose each other. The first resin layer contains a resin and transparent conductive particles. The transparent conductive particles have an average particle size of 1 nm to 100 nm. A ratio of a polymer of an energy curable resin raw material having a long diameter of 1 μm to 10 μm in the first resin layer is 70 pieces/mm3 or less.