Optical Element Resin Layer Molding Air Bubble Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
During the formation of multiple layers in optical element manufacturing, air bubbles tend to get trapped due to the protrusion of the second layer's external circumference beyond the first layer, leading to a degraded appearance and potential incorporation of gases into the optical element.
Innovation Solution
The method involves molding subsequent layers such that their external circumferential parts are located inward from the external circumferential parts of the layers closer to the base material, using resin materials with specific viscosity ranges (200-800 mPa·s and 3000-7000 mPa·s) for the first and second layers, respectively, to prevent air bubble incorporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the second layer is molded with a larger outside diameter than the first layer, then the optical element can accommodate larger aperture requirements, but air bubbles get trapped in the protruding external circumferential part of the second layer
Solution Approach 1:
The patent applies preliminary action by controlling the molding process parameters before the actual molding occurs. Specifically, the resin material for the second layer is prepared with a viscosity of 3000-7000 mPa·s, and the molding is conducted with the external circumferential part of the second layer positioned inward from the first layer's external circumference. This preliminary preparation of resin viscosity and positioning prevents air bubble entrapment before the molding completes.
Solution Approach 2:
The patent changes the physical parameter of resin viscosity to resolve the contradiction. By specifying that the resin material for the second layer shall have a viscosity of 3000-7000 mPa·s during molding, the patent optimizes the flow characteristics of the resin to prevent air bubble entrapment while still allowing the second layer to achieve the required larger outside diameter for aperture requirements.
2Reliability
If the resin material viscosity is increased to 3000-7000 mPa·s for the second layer, then air bubble incorporation is prevented, but the resin becomes more difficult to pour and fill the mold completely
Solution Approach 1:
The patent optimizes the viscosity parameter to a specific range of 3000-7000 mPa·s for the second layer resin material. This parameter change balances two opposing requirements: high enough viscosity to prevent air bubble entrapment during molding, yet low enough to allow complete filling of the mold cavity. The controlled viscosity ensures reliable air bubble prevention while maintaining manufacturability.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the external circumferential part of the second layer inward from the first layer's external circumference before molding. This preliminary positioning, combined with the controlled viscosity, ensures that the resin can be poured and filled completely without trapping air bubbles in the protruding regions.
3Manufacturing precision
If the external circumferential part of the second layer is positioned inward from the first layer, then air bubbles are prevented from being trapped, but the optical element cannot achieve larger aperture in the second layer
Solution Approach 1:
The patent changes the viscosity parameter of the resin material to 3000-7000 mPa·s, which allows the second layer to be molded with external circumferential part positioned inward from the first layer without preventing aperture growth. The optimized viscosity enables the resin to flow and fill the mold completely, achieving both air bubble prevention and larger aperture requirements.
Solution Approach 2:
The patent applies preliminary action by positioning the external circumferential part of the second layer inward from the first layer's external circumference before the molding process. This preliminary positioning, combined with controlled resin viscosity, prevents air bubble entrapment while still allowing the second layer to achieve the required aperture size through proper resin flow and filling.
Data Source
AI summary
An optical element formed by stacking each of two resin layers on a glass substrate, wherein when the second resin layer of the two resin layers counting from the glass substrate is formed, an external circumferential part of the second resin layer is formed so as to be located inward of the outer circumferential part of the first resin layer, which is located closer to the glass substrate than the second resin layer.