Multi-layer VR Lens Segmentation for Shrinkage Control
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Solution Overview
Problem
Conventional single solid lenses for augmented and virtual reality products face challenges such as extended cooling cycle times, high shrinkage factors, warping, and unpredictable shape maintenance due to their thickness, which require high pressure and costly equipment, leading to increased costs and reduced precision.
Innovation Solution
A multi-layer lens approach where a first layer is created and then combined with a second layer through injection molding or casting, allowing for a more precise and cost-effective manufacturing process with minimal material shrinkage and reduced stress, enabling the creation of lenses with flanges for accurate mounting and integration of optical effects like 3D or hologram effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional single solid lens is used for virtual reality optics, then the lens can be manufactured as a single piece, but the cooling cycle time is extended and manufacturing precision deteriorates due to thickness-related shrinkage and warping
Solution Approach 1:
The lens is divided into multiple layers (first layer lens and second layer lens) that are manufactured separately and then combined. This segmentation allows each layer to be thinner and cooler faster, reducing shrinkage and warping while maintaining the ability to manufacture as a unified optical element. The first layer lens is created by casting or injection molding, then a second layer lens is injection molded onto it, creating a multi-layer structure that solves the precision problem.
2Device complexity
If a thick single solid lens is used, then the lens structure is simple, but the cooling cycle time increases and manufacturing cost increases due to required high pressure equipment
Solution Approach 1:
By dividing the thick lens into multiple thinner layers, the cooling cycle time is reduced because each layer has less material to cool. The first layer is cast or injection molded, then the second layer is injection molded onto it. This segmented approach maintains structural simplicity while dramatically reducing cooling time and eliminating the need for high pressure equipment.
Solution Approach 2:
The first layer lens is created and cooled to a threshold temperature or stress level before the second layer is added. This preliminary action ensures the first layer is stable and ready for bonding, reducing overall manufacturing time while maintaining structural integrity.
3Ease of manufacture
If a thick single solid lens is used, then the lens can be manufactured in one process, but material shrinkage increases and manufacturing precision deteriorates
Solution Approach 1:
The manufacturing process is segmented into multiple steps: creating the first layer lens, cooling it to threshold temperature, and then injection molding the second layer onto it. This segmentation reduces material shrinkage because each layer is thinner and experiences less shrinkage individually, while the combined structure achieves the desired optical properties.
4Manufacturing precision
If high pressure equipment is used to maintain shape in thick lenses, then shape control improves, but manufacturing cost increases
Solution Approach 1:
By segmenting the lens into multiple thinner layers, the patent eliminates the need for high pressure equipment. Each layer is thin enough to maintain its shape during cooling without requiring high pressure, significantly reducing manufacturing cost while achieving the same shape control precision through the multi-layer construction.
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 significantly reduces cycle times, minimizes stress and birefringence, and allows for more precise shape control, resulting in lower-cost, high-precision lenses with improved mounting accuracy and optical performance, potentially doubling cavitation and reducing manufacturing energy consumption.
Implementation Method 1
detecting a cooling of the first layer lens to a threshold temperature
Implementation Method 2
detecting the first layer lens is at a threshold stress level
Implementation Method 3
injection molding a second layer lens on the first layer lens
Data Source
AI summary
Methods, systems, and apparatuses for creating or using a multi-layer lens. The processor may create a first layer lens, cool the first layer lens, and combine the first layer lens with a second layer lens to create a multi-layer lens.