Optical Element Splicing With Interference-Fit Alignment
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Solution Overview
Problem
Existing methods for manufacturing large-sized optical elements with microstructure layers on both sides face challenges due to manufacturing limitations, leading to positional deviations and reduced performance and light output when smaller elements are bonded or spliced using optical glue or clamps.
Innovation Solution
A method involving injection integral molding to create optical elements with protrusions and recesses that allow for precise alignment and splicing, ensuring parallel alignment of microstructure layers, using materials like glass, PET, PC, PMMA, and ABS, and employing interference fitting to minimize positional deviation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical glue is used to bond optical elements, then the optical elements can be assembled, but the optical glue shrinks after curing causing positional deviation and affecting performance
Solution Approach 1:
The patent introduces a positioning structure consisting of protrusions on one optical element and corresponding recesses on another optical element. This positioning structure acts as an intermediary mechanism that ensures accurate alignment during assembly, eliminating the need for optical glue and preventing the positional deviation caused by glue shrinkage.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (optical glue) with a mechanical positioning and fixation system. The protrusions fit into recesses to provide precise positioning, and clamps are used to apply uniform pressure during bonding, substituting the chemical adhesive process with a mechanically-controlled assembly process that maintains positional accuracy.
2Ease of manufacture
If clamps are used to assemble and splice optical elements, then assembly can be performed, but assembly deviation occurs due to clamp errors making alignment difficult
Solution Approach 1:
The patent incorporates positioning structures (protrusions and recesses) directly into the optical elements during their manufacturing process. This preliminary action ensures that when the elements are assembled using clamps, the alignment is already predetermined by the fitted protrusions and recesses, eliminating assembly deviation caused by clamp errors.
Solution Approach 2:
The positioning structure serves as an intermediary between the optical elements and the clamps. The protrusions fitting into recesses provide a reference framework that guides the clamps to apply pressure at the correct positions, ensuring accurate alignment even when using simple clamping tools.
3Area of stationary object
If multiple smaller optical elements are spliced to create large-sized elements, then larger optical elements can be obtained, but the splicing process causes positional shifts affecting light output
Solution Approach 1:
The patent divides large optical elements into multiple smaller optical elements that can be manufactured separately using existing manufacturing equipment. Each smaller element is equipped with positioning structures (protrusions or recesses) that enable precise splicing when assembled, allowing the creation of large-sized optical elements without sacrificing relative position accuracy.
Solution Approach 2:
The positioning structures act as intermediary features that facilitate accurate splicing between multiple optical elements. The protrusions on one element fit into recesses on adjacent elements, creating a precise modular assembly system that maintains relative position accuracy across the entire large-sized optical element.
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
The method ensures accurate splicing with reduced positional deviation, enhancing the performance and light output efficiency of the spliced optical elements, allowing for larger sizes up to 3000 mm×3000 mm without performance loss.
Implementation Method 1
employing interference fitting to minimize positional deviation
Data Source
AI summary
Embodiments of the present disclosure relates to a method for splicing optical elements. The method includes providing and splicing a first optical element and a second optical element. The first optical element includes a first substrate having a first splicing surface and at least one protrusion protruding from the first splicing surface toward a side away from the first substrate. The second optical element includes a second substrate having a second splicing surface and at least one recess recessed from the second splicing surface toward the second substrate. After the first optical element and the second optical element are spliced, the first splicing surface is joined to the second splicing surface, and each recess is interference-fitted with a corresponding one protrusion.