Optical Member Molding with Rigid Frame for Surface Parallelism

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Solution Overview

Problem

Existing methods for manufacturing plastic lenses struggle with adjusting the parallelism of main surfaces due to adhesive tape deformation during polymerization, leading to challenges in achieving high accuracy in optical information transmission.

Innovation Solution

A method involving the use of a frame-shaped member with a Young's modulus of 1.0 GPa or more during the polymerization of a thermally polymerizable composition, where the composition is filled inside a mold configured by disposing the frame-shaped member between two mold members and heated to a polymerization initiation temperature, ensuring minimal deformation and high parallelism of main surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a molding agent is used to prevent resin aggregate during compression molding, then manufacturing precision is improved, but the molding agent remains as residue affecting optical quality

Engineering Contradiction:

Improveuniformity of refractive indexVSAvoidoptical quality degradation

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and removes the molding agent from the final product by dissolving it in a solvent after the sintering process. The molding agent residue is extracted using a solvent treatment step, where the sintered compact is immersed in a solvent that dissolves the molding agent, thereby eliminating the harmful residue while maintaining the manufacturing precision benefits.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention introduces a solvent as an intermediary substance to facilitate the removal of the molding agent. The solvent acts as a mediator between the molding agent residue and the final product, enabling the selective dissolution and removal of the harmful residue without affecting the optical member's structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If multiple process steps are used to remove molding agent residue, then optical quality is improved, but production time increases

Engineering Contradiction:

Improvemolding agent residueVSAvoidproduction cycle time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The invention merges multiple process steps into a single integrated solvent treatment step. Instead of separate steps for removing molding agent residue, the patent combines dissolution, extraction, and cleaning into one unified solvent treatment process, thereby reducing the total number of steps and shortening production time while maintaining optical quality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention implements continuous solvent treatment where the sintered compact is continuously immersed and agitated in the solvent during the extraction process. This continuous action ensures complete removal of molding agent residue in a single prolonged step rather than multiple intermittent steps, improving efficiency and reducing total processing time.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If conventional compression molding is used without molding agent, then production is simplified, but resin aggregate occurs reducing manufacturing precision

Engineering Contradiction:

Improvemolding process complexityVSAvoidresin aggregate uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The invention applies preliminary action by incorporating the molding agent into the green compact before sintering. The molding agent is mixed with the resin powder and compacted in advance, creating a uniform distribution that prevents resin aggregate during the subsequent sintering process. This preliminary incorporation ensures manufacturing precision without requiring complex molding procedures.

Inventive Principle:

Principle #10Preliminary action

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 method enables the production of optical members with excellent parallelism of main surfaces, enhancing the accuracy of optical information transmission.

Implementation Method 1

dissolving the molding agent in a solvent

Methodology Applied

Scientific EffectDissolution: Solvation

Implementation Method 2

removing the molding agent with the use of ultrasonic waves

Methodology Applied

Scientific EffectUltrasonic cavitation: Acoustic Cavitation

Data Source

PatentEP4032676B1Method for producing optical member and optical member

Publication Date: 2026.05.06 MITSUI CHEMICALS INC

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AI summary

A method of manufacturing an optical member by curing a thermally polymerizable composition by heating includes, in the following order: a first step of filling an inside of a mold with the thermally polymerizable composition in which the mold is configured by disposing a frame-shaped member, with a Young's modulus of 1.0 GPa or more at a polymerization initiation temperature of the thermally polymerizable composition, between two mold members facing each other; and a second step of heating the mold to the polymerization initiation temperature or more.