Optical Assembly Adhesive with Semi-Solid State for Wick Phenomenon Control
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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 subsequent issues with adhesive strength and optical performance, as the adhesive can either be too fluid, causing uneven contact, or overly solidified, resulting in weak physical bonding.
Innovation Solution
An optical assembly is developed using an adhesive with both photo-curable and thermally-curable portions, where the photo-curable portion is bonded to the second optical film during curing, and the thermally-curable portion is pre-cured in a semi-solid state to minimize flowability and enhance chemical bonding, thereby controlling the contact area and improving adhesive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the adhesive layer is in liquid state to guarantee enough contact area, then adhesive stability is improved, but wick phenomenon occurs and optical property deteriorates
Solution Approach 1:
The patent changes the physical state parameter of the adhesive from liquid to semi-solid by adding filler particles. This transformation maintains sufficient contact area for adhesion while reducing flowability to eliminate wick phenomenon, thereby resolving the contradiction between adhesive stability and optical property
Solution Approach 2:
The patent creates a composite adhesive material by combining resin with filler particles (such as inorganic powder). This composite structure provides both the bonding capability of the resin and the flow control of the filler, achieving stable adhesion without wick phenomenon
2Object-affected harmful factors
If the adhesive layer is solidified first to reduce wick phenomenon, then wick phenomenon is reduced, but adhesion force becomes weaker due to physical bonding only
Solution Approach 1:
The patent maintains the adhesive in a semi-solid state (not fully solidified) by controlling the resin-to-filler ratio and particle size. This allows the adhesive to remain sufficiently fluid for chemical bonding while having reduced flowability to minimize wick phenomenon, achieving both goals simultaneously
3Stability of the object's composition
If the contact area during adhesion is increased to improve adhesive stability, then adhesive stability is improved, but optical gain deteriorates
Solution Approach 1:
The patent optimizes the balance between contact area and adhesive thickness by using semi-solid adhesive with controlled flowability. This ensures sufficient contact area for stable bonding while maintaining appropriate adhesive layer thickness to preserve optical gain, resolving the contradiction between stability and optical performance
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 reduces the 'wick phenomenon, enhances adhesive strength, and improves optical gain by optimizing the weight ratio and curing processes of the adhesive, ensuring precise control over the bonding process and maintaining high optical performance.
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 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 mixed with the photo-curable portion, wherein the weight ratio of the thermally-curable portion of the adhesive to the adhesive is less than 5%; and a second optical film comprising a photo-curable material, wherein the adhesive is bonded to the second optical film through the bonding between the photo-curable portion of the adhesive and the photo-curable material of the second optical film.