Optical Article Surface Roughness for Direct Lamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current optical articles, such as spectacle lenses, lack a suitable form for direct lamination with pressure-sensitive adhesive layers and thermoplastic films, which is necessary for enhancing performance, modifying surface quality, and adding protective and functional coatings, due to insufficient surface roughness features.
Innovation Solution
An optical article with convex and concave surfaces having specific roughness features, such as arithmetic average profile roughness (Ra) between 0.01 μm and 0.3 μm and root mean square slope (Rdq) between 0.2° and 1.2°, allowing for simultaneous lamination of a pressure-sensitive adhesive layer and a thermoplastic film, which cannot be separated after lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional optical articles with smooth surfaces are used, then optical clarity is maintained, but they are unsuitable for direct lamination with adhesive layers and thermoplastic films
Solution Approach 1:
The patent applies parameter changes by modifying the surface roughness characteristics within specific ranges (Ra: 0.01-0.3 μm, Rdq: 0.2°-1.2°) to enable direct lamination. This controlled change in surface parameters allows the optical article to receive adhesive layers and thermoplastic films directly without additional machining steps, resolving the contradiction between ease of manufacture and manufacturing precision.
2Ease of manufacture
If multiple machining steps are performed to achieve suitable surface roughness, then lamination suitability is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent implements preliminary action by pre-configuring the optical article with the appropriate surface roughness parameters during the initial manufacturing process. This preliminary preparation ensures the surface is ready for direct lamination without requiring subsequent machining operations, thereby reducing manufacturing complexity while maintaining lamination readiness.
3Reliability
If surface roughness is increased to enable lamination, then adhesive bonding is improved, but optical quality may deteriorate
Solution Approach 1:
The patent resolves this contradiction by precisely controlling surface roughness parameters within optimized ranges (Ra: 0.01-0.3 μm, Rdq: 0.2°-1.2°). These parameter changes are sufficient to enable reliable adhesive bonding while remaining below thresholds that would compromise optical quality, thus achieving both improved bonding and maintained optical performance.
Data Source
AI summary
An optical article provided in a form suitable for simultaneous lamination of a pressure sensitive adhesive layer and of a thermoplastic film, the said optical article comprising a convex and a concave optical surface, wherein the convex and/or the concave optical surface is a receiving surface intended to receive the pressure sensitive adhesive on which the thermoplastic film is intended to be arranged and wherein the said receiving surface has an arithmetic average profile roughness greater or equal to 0.01 μm and less or equal to 0.3 μm and/or wherein the said receiving surface has a profile roughness root mean square slope greater or equal to 0.2° and less or equal to 1.2°. A method for manufacturing an optical device using said optical article.