Optical Assembly Adhesive with Dual-Cure Mechanism
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Solution Overview
Problem
Conventional optical assemblies face challenges in controlling the contact area during adhesion, leading to the 'wick phenomenon' and resulting in poor optical gain and adhesive strength due to either excessive flowability of liquid adhesives or weaker physical bonding when adhesives are solidified before assembly.
Innovation Solution
An optical assembly with an adhesive comprising both photo-curable and thermally-curable portions, where the photo-curable portion is cured through illumination and the thermally-curable portion is cured via heat treatment, allowing for a semi-solid state that minimizes wick phenomenon while ensuring strong chemical bonding between optical films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a liquid adhesive layer is used during adhesion to ensure enough contact area between the adhesive and prisms, then adhesive stability is improved, but the wick phenomenon occurs and optical gain deteriorates
Solution Approach 1:
The patent changes the physical state parameter of the adhesive from liquid to semi-solid by adding filler particles. This parameter change reduces the adhesive's flowability and eliminates the wick phenomenon while maintaining sufficient contact area for adhesion. The semi-solid state achieves both reliable bonding and optical performance.
Solution Approach 2:
The patent creates a composite adhesive material by combining a base adhesive with filler particles (such as silica, alumina, or titania). This composite structure provides both the bonding capability of the adhesive and the flow-control properties of the filler particles, eliminating the wick phenomenon while maintaining adhesion strength.
2Object-generated harmful factors
If the adhesive layer is solidified before adhesion to reduce wick phenomenon, then optical gain is improved, but adhesion force becomes weaker due to physical bonding only
Solution Approach 1:
The patent changes the consistency parameter of the adhesive from liquid to semi-solid using filler particles. This allows the adhesive to be applied in a controlled state that prevents wick phenomenon while maintaining enough flowability to form strong chemical bonds with both surfaces, achieving both optical gain and strong adhesion.
3Strength
If the contact area between adhesive and prisms is increased to improve adhesive stability, then bonding strength is improved, but optical gain deteriorates
Solution Approach 1:
The patent changes the flowability parameter of the adhesive by adding filler particles to create a semi-solid state. This controlled consistency allows the adhesive to maintain optimal contact area for strong bonding without excessive spread, thereby achieving both high adhesion strength and good optical gain.
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 effectively controls the contact area and adhesive strength, enhancing optical gain and preventing peeling issues by optimizing the weight ratio and thickness of the adhesive layers, thereby improving the overall performance of the optical assembly.
Implementation Method 1
the photo-curable portion of the adhesive is being bonded to the photo-curable material of the second optical film when the photo-curable portion of the adhesive is being cured
Implementation Method 2
the thermally-curable portion of the adhesive has been cured
Data Source
AI summary
The present invention discloses an optical assembly. The optical assembly comprises: a first optical film having a first surface; an adhesive disposed on the first surface of the first optical film, wherein the adhesive comprises a photo-curable portion and a thermally-curable portion; and a second optical film comprising a photo-curable material bonded to the photo-curable portion of the adhesive, wherein the photo-curable portion of the adhesive is being bonded to the photo-curable material of the second optical film when the photo-curable portion of the adhesive is being cured and the thermally-curable portion of the adhesive has been cured.