Optical Filter Bonding Layer for Moisture-Stable Color Reproduction
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Solution Overview
Problem
The adhesion between phosphate-based glass and organic materials used in optical filters is insufficient, particularly in the presence of water, leading to issues with color reproducibility and interference shifts due to varying angles of light incidence.
Innovation Solution
An optical filter design incorporating an absorbing glass substrate composed of phosphate-based or fluorophosphate-based glass, a bonding layer with Si, Ti, Zr, or Al atoms, and a resin layer, where the bonding layer includes hydrolyzed and dehydrated condensates of specific coupling agents, enhancing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reflective film (UVIR film) is provided on a glass substrate to block ultraviolet light and near infrared light, then color reproduction is improved, but adhesion between the glass substrate and resin layer becomes insufficient, particularly in the presence of water
Solution Approach 1:
The patent introduces a bonding layer as an intermediary between the glass substrate and the resin layer. This bonding layer contains specific organic compounds (silane coupling agents) that chemically bond to both the glass substrate and the resin, creating a strong adhesive interface. The bonding layer acts as a mediator that resolves the adhesion problem between the reflective film/coating and the resin layer, particularly in humid environments where direct bonding would fail.
Solution Approach 2:
The patent creates a composite structure consisting of multiple layers: glass substrate, reflective film, bonding layer, and resin layer. Each layer has specific properties that contribute to the overall performance. The bonding layer is a composite material containing silane coupling agents that provide both chemical bonding capability and environmental stability, combining the benefits of strong adhesion with resistance to moisture degradation.
2Reliability
If light-absorbing substrates and absorbing resin layers are used to reduce ultraviolet and near infrared light, then incidence characteristics are improved, but manufacturing complexity increases due to multiple components
Solution Approach 1:
The patent combines multiple functions into a unified structure. The bonding layer serves multiple purposes: it provides adhesion between layers, acts as an additional optical filtering layer, and ensures environmental stability. By merging the adhesion function with optical filtering capabilities in the bonding layer, the patent reduces the need for separate absorbing resin layers, thereby simplifying the overall manufacturing process while maintaining excellent incidence characteristics.
3Ease of manufacture
If conventional bonding methods are used between glass substrate and resin layer, then manufacturing is simple, but adhesion fails in the presence of water leading to interference shifts
Solution Approach 1:
The patent changes the chemical parameters of the bonding interface by incorporating silane coupling agents in the bonding layer. These agents undergo hydrolysis and condensation reactions to form strong covalent bonds with both the glass substrate and the resin layer. The chemical composition and bonding mechanism are fundamentally changed from simple physical adhesion to chemical bonding, which provides stability in the presence of water while remaining compatible with existing manufacturing processes.
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 solution provides improved adhesion between the glass substrate and resin layer, maintaining color reproducibility and reducing interference shifts even with high-oblique light incidence.
Implementation Method 1
the bonding layer includes hydrolyzed and dehydrated condensates of one or more coupling agents
Implementation Method 2
the bonding layer includes hydrolyzed and dehydrated condensates of one or more coupling agents
Implementation Method 3
improved adhesion between the glass substrate and resin layer
Implementation Method 4
an absorbing glass substrate composed of phosphate-based glass or fluorophosphate-based glass; a resin layer... where the bonding layer includes... enhancing adhesion
Data Source
AI summary
Provided is an optical filter, including an absorbing glass substrate composed of phosphate-based glass or fluorophosphate-based glass; a bonding layer with a single layer structure; and a resin layer, wherein the resin layer is provided on the absorbing glass substrate through the bonding layer, wherein the bonding layer includes a Si atom and one or more selected from a Ti atom, a Zr atom, and an Al atom; or an optical filter, including an absorbing glass substrate composed of phosphate-based glass or fluorophosphate-based glass; and a resin layer, wherein the resin layer includes a Si atom and one or more selected from a Ti atom, a Zr atom, and an Al atom, and is provided on the absorbing glass substrate.