Lens Film Bonding With Center-to-Edge Bubble Control
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Solution Overview
Problem
The existing methods for bonding a film to a lens often result in the film extending and losing its initial shape, affecting the surface precision and optical performance of the optical element, and the high temperatures involved can further compromise the mechanical and optical performance.
Innovation Solution
A method involving aligning the lens and film using boundary information from full apertures, gradually bonding from the middle to the edge, and using deformable flexible jigs to ensure even deformation without heating the film into a curved shape, along with controlled temperature differences and debubbling processes to enhance bonding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the film is hot-bent to match the lens curvature, then the film can be bonded to the lens, but the film extends and cannot maintain its initial pre-bending shape, affecting surface precision
Solution Approach 1:
The patent changes the temperature parameter by maintaining the film at heating temperature throughout the bonding process. This allows the film to remain in a soft, deformable state during bonding, preventing extension and shape loss that occurs with traditional hot-bending followed by cooling.
Solution Approach 2:
The patent performs preliminary heating of the film to its bonding temperature before the actual bonding operation. This preliminary action ensures the film is in the optimal soft state for bonding, allowing it to conform to the lens surface without extending or losing its predetermined shape.
2Shape
If traditional hot-bending and stretching processes are used to shape the film, then the film can conform to the lens, but optical performance or mechanical performance of the film is likely affected
Solution Approach 1:
The patent changes the temperature parameter from traditional room-temperature or post-bending heating to continuous heating at bonding temperature throughout the entire bonding process. This parameter change allows the film to remain soft and deformable during bonding, achieving conformity without the need for aggressive stretching or softening processes that would compromise optical and mechanical performance.
3Ease of manufacture
If the film is heated to high temperatures for bonding, then the film can be deformed and bonded, but optical performance or mechanical performance of the film is likely affected
Solution Approach 1:
The patent optimizes the temperature parameter by maintaining the film at a moderate bonding temperature throughout the process, rather than using high-temperature heating. This temperature optimization enables the film to remain sufficiently soft for bonding while avoiding the thermal damage that would affect optical and mechanical performance.
4Shape
If complex processes such as heating, pressure preservation, stretching, and softening are used, then the film can be shaped and bonded, but the bonding method becomes complicated and energy consumption increases
Solution Approach 1:
The patent simplifies the process by changing the temperature parameter to a constant bonding temperature maintained throughout the entire bonding operation. This eliminates the need for multiple heating and cooling cycles, pressure preservation steps, and separate softening processes, thereby reducing overall process complexity while achieving the desired film shaping and bonding.
Data Source
AI summary
A method for bonding a film to a lens and a device for bonding a film to a lens includes a first jig and a second jig that are controlled to move relative to each other, to gradually bond a middle position to an edge position on the lens to the film, so that bubbles between the film and the lens can be reduced, and a good film bonding effect can be achieved. In addition, the method can be performed without processing the film in advance, and obtaining the lens through injection molding after the film is formed, so that optical performance or mechanical performance of the bonded film can be ensured.