Optical Substrate Bonding With Symmetric Tension for Parallel Alignment
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Solution Overview
Problem
Existing methods for bonding organic optical elements to mineral optical elements often result in deformation, leading to loss of optical accuracy due to non-homogeneous load distribution and fragility issues, particularly with rigid glues and tampon or deformable membrane methods.
Innovation Solution
A method involving the application of a symmetric tension to the edges of the organic substrate before curing an adhesive layer, ensuring the substrate is rigorously parallel to the mineral substrate, thereby correcting deformations and achieving homogeneous bonding without significant surface heterogeneities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid glue is used for bonding organic optical element to mineral optical element, then bonding strength is improved, but load distribution homogeneity deteriorates
Solution Approach 1:
The patent changes the physical state parameter of the adhesive from rigid to liquid, allowing it to flow and adapt to surface irregularities. This parameter change enables the adhesive to distribute loads more uniformly across the bonding interface while maintaining strong bonding, resolving the contradiction between bonding strength and load distribution homogeneity
Solution Approach 2:
The patent employs a liquid adhesive that behaves like a flexible medium, conforming to the surface topology of both optical elements. This flexible adhesive layer accommodates surface variations and ensures homogeneous load distribution, preventing the edge effects and non-uniform stress concentration that occur with rigid adhesives
2Stress or pressure
If high loads are applied for bonding by tampon or deformable membrane, then bonding pressure is improved, but substrate deformation and fragility increase
Solution Approach 1:
The patent replaces the mechanical tampon or deformable membrane system with a liquid adhesive system. The liquid adhesive is deposited and allowed to spread under controlled conditions, eliminating the need for high mechanical loads. This substitution achieves adequate bonding pressure without the substrate deformation and fragility issues caused by high-load mechanical bonding methods
Solution Approach 2:
The patent applies preliminary action by depositing the liquid adhesive before bonding and allowing it to spread and penetrate the interface beforehand. This preliminary adhesive application creates a bonding layer that distributes pressure uniformly, preventing localized high-stress concentrations that would deform or damage the substrates during the bonding process
3Ease of manufacture
If organic optical element is bonded without tension control, then bonding simplicity is improved, but optical accuracy deteriorates due to deformation
Solution Approach 1:
The patent utilizes the viscosity parameter of the liquid adhesive, allowing it to flow and spread automatically under minimal pressure. This parameter change enables the adhesive to self-level and conform to the bonding surfaces without requiring complex tension control mechanisms, achieving both bonding simplicity and optical accuracy by eliminating deformation through controlled adhesive flow rather than mechanical tension
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 ensures precise and homogeneous bonding, minimizing deformation and fragility risks, while allowing for the use of liquid glues and reducing the need for high loads, thus maintaining optical accuracy and enhancing the stability of the bonded assembly.
Implementation Method 1
Curing the adhesive layer to induce a polymerization of the adhesive layer
Data Source
AI summary
A method for manufacturing an optical article including the following steps: a. providing a first substrate with a main surface, b. depositing a second substrate on the main surface with an adhesive layer so that the space between the first substrate and second substrate is filled by the adhesive layer, c. curing the adhesive layer to induce a polymerization of the adhesive layer, wherein a tension step takes place after steps a. and b., and before step c., the tension step including applying symmetrically a tension, preferentially with a central symmetry, preferentially a radial isotropic tension or an ortho-distributed symmetrical tension, on the edges of the second substrate sensibly in a tension plan parallel to a plan representative of the main surface.