Transparent Optical Element Cell Filling via Deformable Membrane
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Producing transparent optical elements with cells filled uniformly to avoid optical defects such as diffraction and scattering, which affect transparency and dioptric quality, is challenging due to issues like bubble formation and uneven filling.
Innovation Solution
A method involving the deposition of a liquid substance with optical properties onto an optical component with cells, where the excess substance is pushed over the cell walls to fill all cells uniformly, using a deformable membrane to minimize pressure and prevent deformation or damage, and optionally sealing the cells with a transparent film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressure is applied to fill the cells with liquid substance, then the filling speed increases, but the optical component may deform or cell walls may be damaged
Solution Approach 1:
The patent uses a deformable membrane to apply dynamic, controlled pressure to the liquid substance. The membrane can be deformed by suction to push the liquid progressively over the cell walls, providing just enough pressure to ensure complete filling while avoiding excessive pressure that would deform the optical component or damage cell walls.
Solution Approach 2:
The deformable membrane acts as an intermediary between the suction force and the liquid substance. Instead of applying pressure directly to the cells, the membrane transfers the force gradually through the liquid, allowing controlled pushing of the liquid over the cell walls without direct mechanical contact that could cause damage.
2Manufacturing precision
If a large quantity of liquid substance is deposited on the cells, then all cells can be completely filled, but excess substance is wasted
Solution Approach 1:
The deformable membrane system allows the liquid substance to be pushed only as far as needed to fill the cells. The membrane is deformed by suction to advance the liquid front progressively, and when the cells are filled, the pushing stops automatically. This self-regulating mechanism ensures complete filling without requiring a large excess of substance.
Solution Approach 2:
The patent acknowledges that some excess substance will remain after filling, but the deformable membrane method minimizes this excess compared to other filling methods. The controlled pushing action ensures that substance is not wasted through premature overflow or excessive deposition, and the remaining excess can be recovered for reuse.
3Productivity
If the liquid substance is pushed forcefully over the cell walls, then filling is more rapid, but bubbles may be trapped in the cells
Solution Approach 1:
The deformable membrane provides dynamic control over the liquid pushing process. By deforming the membrane through suction, the liquid is pushed gradually and continuously over the cell walls, allowing air bubbles to escape ahead of the liquid front. This dynamic control prevents bubble entrapment that would occur with sudden, forceful filling.
Solution Approach 2:
The method ensures that cells are filled in a controlled sequence where the liquid front advances progressively. The deformable membrane is deformed to push liquid over the walls just enough to allow complete filling, and this controlled preliminary action prevents bubbles from being trapped during the filling process.
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
Ensures complete and uniform filling of cells without bubbles, maintaining transparency and optical quality, while reducing the risk of deformation or damage to the component, and allowing for efficient reuse of excess substance.
Implementation Method 1
a deformable membrane can be used to push the substance onto the set of cells. For example, the membrane can be retained by a peripheral edge thereof, and be brought above the set of cells. It is then deformed to come into application against the optical component. It can be deformed by suction, in particular, by creating a depression between the component and the membrane.
Implementation Method 2
The substance with an optical property is adapted so that a contact angle of this substance with the optical component is less than 90°, at the location of the cells. For this, a surfactant can optionally be added to the substance with an optical property, to adjust a surface tension of the latter.
Data Source
Figure 1a~4b
AI summary
The invention concerns a method for producing a transparent optical element (1) including filling cells (10) of the element with a substance having an optical property. It consists in moving an amount of the substance (20) radially on the cells, towards a peripheral edge of the optical element, such that the substance penetrates each cell. Optionally, the cells may be sealed with a film (30) fixed on the partition walls (11) of the cells. The filling and the sealing of the cells may be carried out in a single step of the process.