Optical Device Resin Bonding via Wall-Defined Injection
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Solution Overview
Problem
Conventional methods for manufacturing optical devices with large optical members require large vacuum laminating devices and autoclaves, and face challenges with side curing, especially when optical members are adjacent, leading to inefficiencies and incomplete curing of photocurable resin compositions.
Innovation Solution
A method involving the formation of a wall with an opening on one of the optical members or transparent panels to create a resin filling space, where the photocurable resin is injected and cured, eliminating the need for large vacuum laminating devices and side curing steps, and allowing for reliable curing of the resin between multiple optical members and a transparent panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to bond large optical members with transparent panels, then bonding can be achieved, but large vacuum laminating devices and autoclaves are required
Solution Approach 1:
The patent divides the bonding process into segments: first forming a wall structure with an opening on one of the optical members or transparent panels to define a resin filling space, then injecting photocurable resin through the opening, and finally curing the resin. This segmentation eliminates the need for large vacuum laminating devices and autoclaves, as each step can be performed with simpler, more compact equipment.
2Reliability
If photocurable resin composition is applied on light shielding portions, then side curing is performed by irradiating from side surfaces, but incomplete curing occurs when optical members are adjacent
Solution Approach 1:
The patent introduces a wall structure with an opening as an intermediary element. The wall defines a resin filling space and the opening allows photocurable resin to be injected directly into the bonding region. This intermediary structure enables complete curing by allowing light to reach all areas of the resin without being blocked by adjacent optical members or light shielding portions, eliminating the need for complex side curing procedures.
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 approach eliminates the need for large vacuum laminating devices and autoclave processes, ensures complete curing of the photocurable resin, and allows for the reliable bonding of multiple optical members to a transparent panel without side curing, enhancing manufacturing efficiency and consistency.
Implementation Method 1
a step of curing the photocurable resin composition to form the cured resin layer
Data Source
Figure 1A~1B
Figure 2A~3
Figure 4
AI summary
Provided is a method for manufacturing an optical device capable of surely curing a photocurable resin composition. The method for manufacturing an optical device 1 in which an optical member 2 and a transparent panel 4 are bonded together via a cured resin layer 3 includes: a step of forming, on one of the optical member 2 and the transparent panel 4, a wall 12 surrounding a forming region for the cured resin layer 3 and having at least one opening 13; a step of laminating the optical member 2 and the transparent panel 4 to form a laminated body 10 in which a resin filling space 14 surrounded by the wall 12 is formed between the optical member 2 and the transparent panel 4; a step of filling the resin filling space 14 of the laminated body 10 with a photocurable resin composition 30; and a step of curing the photocurable resin composition 30 to form the cured resin layer 3.