Self-Supporting Optical Adhesive for Rigid Substrate Lamination
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Solution Overview
Problem
Rigid optical laminates face optical losses due to air gaps between substrates, which are difficult to eliminate with traditional anti-reflective coatings and pressure-sensitive adhesives, often resulting in visible air bubbles and refractive index mismatches.
Innovation Solution
A self-supporting optical adhesive with a cross-linked silicone-based polymer network and silicone fluid is used to fill air gaps between rigid optical substrates, allowing for air/bubble-free lamination and eliminating the need for anti-reflective coatings by optically coupling the substrates and enabling temporary or permanent repositionability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If anti-reflective coating layers are applied at air/rigid optical element interfaces, then optical losses are reduced, but manufacturing cost increases and air gaps are not completely eliminated
Solution Approach 1:
The patent extracts and eliminates the harmful air gap between optical elements by replacing it with a refractive index-matched adhesive material. This removes the root cause of optical losses at interfaces, making anti-reflective coatings unnecessary and reducing manufacturing cost.
Solution Approach 2:
The patent changes the refractive index parameter of the bonding material to match that of the rigid optical elements. By selecting an adhesive with a refractive index between 1.4 and 1.6 (matching typical optical elements), the interface becomes optically invisible, eliminating reflections and losses without requiring additional coating layers.
2Strength
If pressure sensitive adhesive is used to laminate rigid optical elements, then bonding is achieved, but visible air bubbles are formed causing optical losses
Solution Approach 1:
The patent changes the viscosity parameter of the adhesive to a specific range (100-10,000 cP) that allows the material to flow and fill air gaps and bubbles during the bonding process. This viscosity optimization enables the adhesive to displace air and achieve complete wetting of the optical surfaces, eliminating bubble formation while maintaining strong bonding.
Solution Approach 2:
The patent uses a composite adhesive system comprising a polymer base material combined with refractive index-matching particles or additives. This composite formulation provides both mechanical bonding strength and optical clarity by eliminating air bubbles and matching the refractive index of the bonded optical elements.
3Ease of manufacture
If air gaps are left between rigid optical elements, then assembly is simplified, but refractive index difference causes optical losses
Solution Approach 1:
The patent changes the refractive index parameter of the bonding material to match that of the rigid optical elements. By selecting an adhesive with a refractive index between 1.4 and 1.6 (matching typical optical elements), the interface becomes optically invisible, eliminating reflections and losses while maintaining assembly simplicity.
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 solution enhances optical performance by reducing glare and increasing transmission, while allowing for the repair or replacement of damaged optical articles without replacing the entire assembly.
Implementation Method 1
An air/rigid optical element interface often has a refractive index difference that can lead to optical losses at that air/rigid optical element interface
Implementation Method 2
a self-supporting optical adhesive disposed between the first rigid substrate and the second rigid substrate. The self-supporting optical adhesive includes a cross-linked silicone based polymer network and a silicone fluid disposed in the polymer network
Data Source
AI summary
An optical article and method or forming an optical article are disclosed. The optical article includes a first rigid optical substrate, a second rigid optical substrates and a self-supporting optical adhesive disposed between the first rigid substrate and the second rigid substrate. The self-supporting optical adhesive includes a cross-linked silicone based polymer network and a silicone fluid disposed in the polymer network.