Patterned Lens Hardcoating for Abrasion Without Optical Blur
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Solution Overview
Problem
Patterned lenses, particularly those with micro lenses, face a challenge in achieving adequate abrasion resistance without compromising their optical performance, as conventional hardcoatings can degrade the optical features when applied.
Innovation Solution
A base layer with a pre-applied hardcoating is integrated during the injection molding process to replicate optical features, followed by a final hardcoating application, ensuring minimal thickness and maintaining optical sharpness while enhancing abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional hardcoating is applied on the surface of the lens to increase abrasion resistance, then the abrasion resistance is improved, but the optical performance of the pattern (micro lenses) is degraded
Solution Approach 1:
The coating is segmented into two distinct layers: a base layer applied during injection molding that provides initial abrasion resistance and surface hardness, and a final thin hardcoating layer applied afterward that provides additional protection without compromising optical features. This segmentation allows each layer to serve its specific function optimally.
Solution Approach 2:
The base layer is applied in advance during the injection molding process, creating a pre-prepared surface that is then ready for the final thin hardcoating application. This preliminary action ensures the optical features are already formed with adequate base protection before the final coating is added.
2Manufacturing precision
If the thickness of the hardcoat is reduced to maintain optical performance, then the optical performance is preserved, but the abrasion resistance provided by the hardcoat is diminished
Solution Approach 1:
The total coating thickness is divided into two parts: a base layer of sufficient thickness applied during molding that provides the primary abrasion resistance, and a final thin hardcoating layer that adds protection without affecting optical features. This segmentation allows the system to achieve both goals.
Solution Approach 2:
The coating system uses composite material structure with a base layer (applied during injection molding) and a final hardcoating layer (applied afterward). This composite approach combines the advantages of both layers: the base layer provides bulk protection and the thin final layer provides surface hardness with minimal optical impact.
3Object-affected harmful factors
If a base layer with pre-applied hardcoating is integrated during injection molding to enhance abrasion resistance, then the abrasion resistance is improved, but the process complexity increases
Solution Approach 1:
The base layer coating application is merged with the injection molding process, occurring simultaneously rather than as a separate step. This integration reduces overall process complexity despite adding the coating functionality, as it combines two operations into one.
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 proposed method achieves improved abrasion resistance with reduced hardcoating thickness, preserving the optical performance of patterned lenses, particularly those with micro lenses, thereby maintaining their functional efficacy.
Implementation Method 1
dual-cured thermally and/or light-cured coating where the coating is partially cured through a thermal process
Implementation Method 2
a light-cured coating may be utilized where the coating is exposed to a light curing source such as UV, LED, or visible with low dosage after application onto the film
Data Source
AI summary
A patterned lens with abrasion resistance having a base layer hard coat and a top hard coat. The base layer hardcoat may be formed on a film or sheet and used in molding the patterned lens. The top hard coat may be applied after molding.