Abrasion-Resistant Optical Lens Coating That Preserves Microlens Power
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Solution Overview
Problem
Existing optical articles with abrasion-resistant coatings suffer from a reduction or alteration of the optical effects of protruding optical elements, such as microlenses, due to the coating's thickness and material properties, leading to impaired functionality and visibility issues.
Innovation Solution
The optical article design incorporates abrasion-resistant coatings with optical elements that protrude from the coating surface, and the coating is formed simultaneously with the elements using a complementary recess in the base substrate, ensuring the elements maintain their optical power and are fully encapsulated within the article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an abrasion-resistant coating is applied to cover the microlenses on the base-lens substrate, then the protection against scratching is improved, but the optical power of the microlenses is reduced or altered
Solution Approach 1:
The patent extracts the optical elements (microlenses) from beneath the coating by forming them to protrude through the abrasion-resistant coating layer. This allows the coating to provide protection while the protruding optical elements maintain their optical power by being partially exposed, thus resolving the contradiction between protection and optical functionality.
Solution Approach 2:
The patent transitions from a two-dimensional planar coating surface to a three-dimensional structure where optical elements protrude through the coating. By adding the vertical dimension and forming recesses in the substrate that extend through the coating, the design allows both the coating's protective function and the optical elements' functional integrity to coexist.
2Manufacturing precision
If the thickness of the abrasion-resistant coating is reduced to minimize alteration of microlens power, then the optical power alteration is reduced, but the protection properties against scratching are highly reduced
Solution Approach 1:
The patent applies local quality by creating regions of different coating thickness: areas with full coating thickness for maximum protection, and areas where the coating is thinner or absent at the protruding optical elements to maintain their optical power. This localized differentiation resolves the contradiction by optimizing both protection and optical functionality in different regions.
3Manufacturing precision
If the free surface of the abrasion-resistant coating follows the curvature of protruding optical elements, then the optical power is maintained, but the surface exhibits local deformations that alter light refraction
Solution Approach 1:
The patent extracts the optical elements from the coated surface by forming them to protrude through the coating layer. The free surface of the coating remains relatively flat while the optical elements extend beyond it, eliminating the local deformations that would otherwise alter light refraction while maintaining optical power.
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 design preserves the optical functionality of elements like microlenses by controlling the refraction and diffraction, providing enhanced protection against scratches while maintaining the desired optical effects, and allows for additional coatings without surface irregularities.
Implementation Method 1
a ray of light incident on one such deformation undergoes a first refraction when entering into the abrasion-resistant coating, and a second refraction at the interface with the microlens of the base-lens substrate
Data Source
Figure 1a~2b
Figure 3a~4c
Figure 5~6d
AI summary
An optical article (1) is disclosed, comprising: - a base lens substrate (10), having a front surface (101) and a back surface (102), - an abrasion resistant coating (20) covering at least one of said front surface and said back surface, the abrasion resistant coating (20) having a first surface (21, 22) at the interface with the base lens substrate and a second surface (22,21) opposite the first, and - at least one optical element (30) protruding from one of the first and second surfaces of said abrasion resistant coating, said optical element being composed of a material adapted to form an abrasion resistant coating.