Optical Lens Laminate Structure for Bonding and Shape Stability
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Solution Overview
Problem
Existing methods for manufacturing photochromic lenses face challenges in achieving high bonding ability and shape stability of laminates used in optical components and spectacles.
Innovation Solution
A laminate comprising first and second base materials made of polyvinyl alcohol or cellulose resin, bonded by an adhesive layer with a coat layer of epoxy, urethane, or acrylic resin, which enhances bonding to optical element base materials and improves shape stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a binder sheet method is used to manufacture semi-finished lenses, then production efficiency is improved and mass production is facilitated, but bonding ability and shape stability of the laminate are insufficient
Solution Approach 1:
The invention uses a composite laminate structure consisting of a polyvinyl alcohol resin layer, a photochromic compound-containing resin layer, and a cellulose resin layer. This composite structure combines the advantages of each material: the polyvinyl alcohol provides bonding ability, the photochromic compound enables photochromic functionality, and the cellulose resin provides shape stability, thereby resolving the contradiction between production efficiency and reliability.
Solution Approach 2:
The invention modifies the chemical and physical parameters of the resin layers to optimize performance. Specifically, it controls the degree of polymerization of the polyvinyl alcohol resin and the molecular weight of the cellulose resin, and adjusts the composition and concentration of the photochromic compound to achieve both high bonding ability and shape stability while maintaining production efficiency.
2Ease of manufacture
If conventional resin materials are used in the laminate, then manufacturing is simplified, but bonding strength to optical element base materials is insufficient
Solution Approach 1:
The invention optimizes the chemical parameters of the resin materials, specifically using polyvinyl alcohol with controlled degree of polymerization and cellulose resin with controlled molecular weight. These parameter changes enhance the bonding strength to optical element base materials while maintaining ease of manufacture through conventional lamination processes.
Solution Approach 2:
The invention employs a composite resin system where polyvinyl alcohol and cellulose resin work synergistically. The polyvinyl alcohol provides strong bonding capability, while the cellulose resin enhances structural integrity and shape stability, achieving high bonding strength without complicating the manufacturing process.
3Device complexity
If the laminate structure is simplified, then manufacturing is easier, but shape stability is insufficient
Solution Approach 1:
The invention uses a three-layer composite structure with distinct functional layers: polyvinyl alcohol resin layer for bonding, photochromic compound-containing resin layer for optical functionality, and cellulose resin layer for shape stability. This structured composite approach provides high shape stability while maintaining reasonable manufacturing complexity.
Solution Approach 2:
The laminate is segmented into functionally distinct layers, with each layer performing a specific function. The cellulose resin layer specifically addresses shape stability, while the polyvinyl alcohol layer handles bonding, and the photochromic layer provides optical functionality. This segmentation allows optimization of each function without excessive overall complexity.
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 laminate provides high bonding strength and shape stability, suitable for use in optical components and spectacles, with the ability to incorporate functional colorants like photochromic compounds.
Implementation Method 1
an adhesive layer, which is provided between the first and second base materials to bond them together
Implementation Method 2
The photochromic compound can form two or more isomers that have different optical absorption spectra and reversibly change into one another under the effect of light
Data Source
AI summary
The purpose of the present invention is to provide: a layered body having excellent adhesion to an optical element base material and excellent shape stability; and an optical article, a lens, and spectacles that include such layered body. According to this embodiment, a layered body is provided. The layered body comprises: a first base material and a second base material; an adhesion layer; and a coating layer. The first and second base materials include a polyvinyl alcohol resin. The adhesion layer is interposed between the first base material and the second base material and adheres these base materials. The coating layer contains a resin and covers at least a portion of the surface of the first base material and/or the second base material. The resin contains at least one type selected from the group consisting of an epoxy resin, a urethane resin, and an acrylic resin.