Optical Element Casting Embeds Structured Coating
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Solution Overview
Problem
There is a need to produce optical elements with embedded optically effective structures in large quantities while maintaining high accuracy and quality, which existing methods struggle to achieve effectively.
Innovation Solution
A method involving a transparent body with an optically effective structure, where a structured section is coated with an optically effective material and covered with a protective layer using thermoplastic or thermosetting materials, ensuring the structure is fully embedded and the boundary surface almost disappears optically, allowing for high-quality production in large quantities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce optical elements with embedded structures, then production can be carried out, but manufacturing precision and quality are insufficient for large-scale production
Solution Approach 1:
The optical element is divided into multiple layers: a first partial body containing the optically effective structure, and a second partial body formed by casting. This segmentation allows the structured section to be precisely manufactured in the first partial body while the second partial body is formed through a high-precision casting process that embeds the structure, enabling both high manufacturing precision and scalability for large quantity production.
2Reliability
If an optically effective structure is embedded in the transparent body, then optical functionality is improved, but the production process becomes more complex
Solution Approach 1:
The optically effective structure is manufactured and embedded in the first partial body before the second partial body is formed through casting. This preliminary action allows the complex structured section to be precisely created in advance, while the subsequent casting process simplifies the overall production by automatically embedding the pre-manufactured structure, thus maintaining optical quality without excessively complicating the production process.
3Stability of the object's composition
If the optically effective structure is completely embedded in the transparent body, then optical homogeneity is improved, but the structured section requires precise coating and embedding processes
Solution Approach 1:
The first partial body acts as an intermediary carrier that contains the structured section with the optically effective coating. This intermediary structure allows precise coating and embedding of the optically effective material before the second partial body is formed by casting. The casting process then encapsulates this intermediary, achieving complete embedding and optical homogeneity while maintaining manufacturing precision through the controlled casting 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
This method enables the production of optical elements with embedded optically effective structures that are accurate and reproducible in large quantities, ensuring high quality and optical homogeneity, suitable for applications like spectacle lenses in display devices.
Implementation Method 1
applying a protective layer which is transparent for the predetermined wavelength range onto the upper side of the first partial body by means of casting thermoplastic material and/or thermosetting material
Data Source
AI summary
A method for producing an optical element includes providing a first partial body which is transparent for the predetermined wavelength range and including on its upper side a structured section, applying a coating which is optically effective for the predetermined wavelength range onto the structured section in order to form the optically effective structure, and applying a cover layer which is transparent for the predetermined wavelength range onto the upper side of the first partial body by means of casting of thermoplastic material and/or duroplastic material.