Optical Element Resin Thickness Gradient for Thermal Stress

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Solution Overview

Problem

Optical elements with resin compositions on transparent bases face issues with environmental durability due to thermal stress, leading to cracking in low temperature environments, despite having excellent optical characteristics.

Innovation Solution

An optical element with a base material having a spherical surface, a flat surface, and a ridge line portion, where the resin portion is uniformly distributed with varying thickness, thicker at the first point between the center and edge, thinner at the second point, and thicker at the ridge line, to manage thermal stress and prevent cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a resin composition is provided on a transparent base material to form an optical element, then excellent optical characteristics are achieved, but cracks occur in the resin due to thermal stress in low temperature environments

Engineering Contradiction:
Improveenvironmental durabilityVSAvoidresin cracking resistance
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The patent applies local quality by creating a resin portion with non-uniform thickness distribution. The resin is made thicker at the center region and thinner at the outer peripheral portion, allowing different regions to handle thermal stress differently. This localized thickness variation reduces stress concentration at the periphery while maintaining optical performance at the center.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent changes the geometric parameter of the resin portion by controlling its thickness to vary continuously from the center to the periphery. This parameter change creates a gradient structure that modifies stress distribution patterns, preventing crack initiation and propagation in low temperature environments.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the resin portion is made thicker to improve durability, then environmental durability improves, but thermal stress concentration increases causing cracking

Engineering Contradiction:
Improveenvironmental durabilityVSAvoidthermal stress
Core Design Contradiction:
ReliabilityVSStress or pressure

Solution Approach 1:

The patent implements local quality by making the resin portion thicker at the center and thinner at the periphery. This localized thickness control ensures that the resin has sufficient mass and strength where needed while reducing stress concentration in regions more prone to thermal stress, thereby preventing cracking.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent converts the potentially harmful uniform thickness design into a beneficial non-uniform thickness profile. By intentionally creating a thickness gradient, the design transforms what would be a simple structural parameter into a stress-management feature, where the varying thickness actively works to distribute and reduce thermal stress.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 optical element achieves excellent optical characteristics and environmental durability by dispersing thermal stress and preventing resin cracking, even in low temperature conditions.

Implementation Method 1

cracks in the resin may occur due to the generation of a large thermal stress on the outer peripheral portion of the lenses

Methodology Applied
Scientific EffectThermal stress: Thermal Expansion

Data Source

PatentUS20240272329A1Optical element with excellent environmental durability
Publication Date: 2024.08.15 CANON KK
  • US20240272329A1 patent drawing
  • US20240272329A1 patent drawing
  • US20240272329A1 patent drawing

AI summary

An optical element includes: a base material; and a resin portion, wherein the base material has a spherical surface, a flat surface surrounding the spherical surface, and a ridge line portion including a ridge line at the boundary between the spherical surface and the flat surface, wherein the resin portion is provided over the spherical surface and over the flat surface straddling the ridge line portion, has a linear expansion coefficient different from a linear expansion coefficient of the base material, has a maximum thickness at a first point between a center and an edge of the spherical surface of the base material, which is thicker than a thickness at the center, has a thickness thinner than the maximum thickness at a second point between the first point and the edge, and has a thickness thicker at the ridge line portion than the thickness at the second point.