Optical Element Rib Structure for High-Speed Roll Forming
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Solution Overview
Problem
Existing methods for manufacturing optical elements with a split lens structure face challenges in high-speed production due to air bubble trapping and increased defect rates, particularly in the formation of regular concavo-convex shapes, which hinders productivity and quality.
Innovation Solution
The implementation of an optical element with a split lens structure and a rib or groove portion that promotes resin flow and suppresses air bubble trapping, featuring a rib or groove structure with a constant height or depth between split lenses, arranged in specific configurations such as blazed, Fresnel, or cylindrical lens arrays, to facilitate smooth resin flow and reduce defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conveying speed is increased to improve productivity, then production efficiency increases, but air bubbles are trapped between the curable resin film and the stamper cylinder, causing defects on the film surface
Solution Approach 1:
The invention divides the stamper cylinder surface into multiple regions: a pressing portion with a regular lens shape for forming the optical element, and a retention portion where resin is pushed and spread in the width direction. This segmentation allows the resin to be properly distributed and deaired in the retention portion before being pressed in the pressing portion, enabling high-speed conveying without air bubble trapping.
Solution Approach 2:
The retention portion performs preliminary resin distribution and spreading in the width direction before the resin reaches the pressing portion. This preliminary action ensures that the resin is properly positioned and air bubbles are eliminated ahead of time, allowing the main pressing operation to proceed at high speed without defect formation.
2Stability of the object's composition
If a retention portion is added to push and spread resin in the width direction, then resin distribution improves, but film formation becomes less stable and condition setting becomes more difficult at high speeds
Solution Approach 1:
The invention applies different functional qualities to different portions of the stamper cylinder: the retention portion has a specific structure for pushing and spreading resin in the width direction, while the pressing portion has a regular lens shape for final forming. This local differentiation optimizes resin distribution without requiring complex adjustments across the entire system, maintaining stability at high speeds.
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 enhances the manufacturing process by reducing defects and increasing productivity while maintaining high-quality optical element formation, even at higher speeds, and allows for the creation of optical elements with improved formability and optical effects.
Implementation Method 1
curing the resin by irradiating the resin with ionizing radiation with the resin of the stamper cylinder brought into contact with the film
Data Source
AI summary
By providing a rib portion 40 having a constant height in the range from 50% to 120% of the height of the highest point of a split lens structure between a plurality of split lenses, even when roll forming is performed at a high speed, trapping of air bubbles can be inhibited, and resin flow can be promoted; therefore, an optical element 10 having a surface on which a lens shape is formed and having a special optical effect can be obtained with few structural defects and high productivity.