Optical Device Production via Spatial Light Modulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional 3D printing technologies face challenges in producing optical devices like optical lenses due to difficulties in achieving internal transparency and accurate shape, particularly at interfaces.

Innovation Solution

A method involving the polymerization of a curable composition using light irradiation with varying intensity, where the first portion is polymerized externally and the second portion through the polymerized first portion, ensuring homogeneous polymerization and controlled shape formation, utilizing a spatial light modulator to adjust light intensity and distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional 3D printing technologies are used to produce optical devices, then production capability is improved, but internal transparency and interface accuracy deteriorate

Engineering Contradiction:

Improveproduction capabilityVSAvoidinterface accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent divides the optical device into multiple layers and processes each layer sequentially through selective light irradiation. The curable composition is polymerized layer by layer, with each layer being cured independently before the next is added, enabling precise control of interfaces while maintaining production efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies light irradiation with locally varying intensity to different regions of the curable composition. By controlling the spatial distribution of light intensity, the polymerization process achieves uniform curing at interfaces while maintaining overall transparency, addressing the precision requirement locally without compromising global quality.

Inventive Principle:

Principle #3Local quality

2Productivity

If conventional 3D printing technologies are used to produce optical devices, then production capability is improved, but internal transparency deteriorates

Engineering Contradiction:

Improveproduction capabilityVSAvoidinternal transparency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent maintains continuous polymerization action by sequentially irradiating adjacent portions of the curable composition without interruption. The light irradiation continuously progresses through the volume, ensuring homogeneous polymerization throughout the optical device, which eliminates internal defects and ensures uniform transparency while maintaining efficient production.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent uses light irradiation with controlled intensity distribution to achieve homogeneous polymerization of the curable composition. By carefully managing the light intensity and exposure time across different portions, the resulting optical device has uniform material properties throughout, ensuring internal transparency while enabling efficient production.

Inventive Principle:

Principle #33Homogeneity

3Manufacturing precision

If light irradiation with varying intensity is used to control shape, then manufacturing precision is improved, but process complexity increases

Engineering Contradiction:

Improveshape control accuracyVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent controls the shape of the optical device by varying the light intensity parameter across different regions of the curable composition. By adjusting the intensity distribution of the light irradiation, the polymerization rate and extent are controlled locally, enabling precise shape control without requiring complex mechanical systems or multiple processing steps.

Inventive Principle:

Principle #35Parameter changes

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 results in transparent and accurately shaped optical devices, such as lenses, with controlled optical properties, suitable for various applications including corrective and protective lenses.

Implementation Method 1

polymerizing a first portion of said volume by irradiating an external surface of said volume with a light irradiation, thereby increasing a transmittance of said first portion for said light irradiation

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

polymerizing a second portion of said volume by irradiating said second portion with said light irradiation through said external surface and the polymerized first portion

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11548215B2Method of producing an optical device and a corresponding system

Publication Date: 2023.01.10 NIKON CORP

AI summary

A method of producing an optical device from a volume of a curable composition, includes the following steps: —polymerizing a first portion of the volume by irradiating an external surface of the volume with a light irradiation, thereby increasing a transmittance of the first portion for the light irradiation; —polymerizing a second portion of the volume by irradiating the second portion with the light irradiation through the external surface and the polymerized first portion, wherein the light irradiation has a light intensity varying over the external surface between a first light intensity and a second light intensity distinct from the second light intensity. A corresponding system is also described.