Sterile Peelable Lens Stacks With Electron Beam Curing
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Solution Overview
Problem
Laminated optical lens stacks with low peel strength suffer from under-curing issues leading to peel creep over time, which is exacerbated by repeated curing processes affecting earlier layers, resulting in inconsistent peel strength and potential optical distortion.
Innovation Solution
A manufacturing method involving sequential coating, heating, and UV exposure of adhesive layers, followed by electron beam curing to ensure uniform crosslinking and complete curing of all layers, while maintaining low peel strength and reducing optical distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If repeated heating and UV curing processes are applied to each successive layer of adhesive, then complete curing of the adhesive is achieved, but under-cured layers lead to peel creep over time
Solution Approach 1:
The patent applies preliminary thermal curing to adhesive layers before UV exposure, ensuring that the adhesive is pre-conditioned and ready for complete curing. This preliminary action prevents under-curing by preparing the adhesive in advance, thereby maintaining consistent peel strength and preventing peel creep over time.
Solution Approach 2:
The patent controls and adjusts curing parameters including temperature, UV exposure time, and adhesive composition to achieve complete and uniform curing. By optimizing these parameters, the patent ensures that all adhesive layers are fully cured without under-curing, thus maintaining stable peel strength and preventing peel creep.
2Ease of operation
If low peel strength adhesive is used to enable lens removal, then lens peelability is achieved, but adhesive under-curing occurs leading to peel creep
Solution Approach 1:
The patent applies preliminary thermal curing to the adhesive before UV exposure, ensuring that the adhesive achieves complete and stable curing. This preliminary action maintains the desired low peel strength for lens removal while preventing under-curing, thereby ensuring both lens peelability and adhesive curing stability.
Solution Approach 2:
The patent optimizes adhesive parameters including composition, thickness, and curing conditions to achieve complete curing while maintaining low peel strength. By carefully controlling these parameters, the patent ensures that the adhesive remains peelable for lens removal while achieving stable curing without peel creep.
3Productivity
If multiple adhesive layers are laminated sequentially, then multi-layer lens stack is produced, but curing inconsistency occurs across layers
Solution Approach 1:
The patent applies preliminary thermal curing to each adhesive layer before UV exposure, ensuring uniform curing across all layers. This preliminary action addresses curing inconsistency by preparing each layer in advance, thereby maintaining manufacturing efficiency while achieving uniform curing throughout the multi-layer lens stack.
Solution Approach 2:
The patent controls and adjusts curing parameters including temperature, UV exposure time, and adhesive composition to achieve complete and uniform curing across all layers. By optimizing these parameters, the patent ensures consistent curing throughout the multi-layer stack, thereby maintaining both production efficiency and manufacturing precision.
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 achieves uniform curing across layers, reduces peel creep, and ensures a sterile stack with consistent peel strength, enhancing the durability and optical quality of laminated lens stacks.
Implementation Method 1
heating the first adhesive coating to evaporate at least some solvent of the first adhesive coating
Implementation Method 2
initiate curing of the first adhesive coating
Implementation Method 3
exposing the first adhesive coating to ultraviolet light to continue curing of the first adhesive coating
Implementation Method 4
exposing the stack of lenses to an electron beam to continue curing of the first adhesive coating and the second adhesive coating
Data Source
AI summary
A method of manufacturing a sterile stack of peelable lenses includes coating a first lens (or stack of lenses) with a first adhesive coating, heating the first adhesive coating to initiate curing, exposing the first adhesive coating to ultraviolet light to continue curing, laminating a second lens (or stack of lenses) onto a surface of the first adhesive coating to produce a stack of lenses, coating the second lens with a second adhesive coating, heating the second adhesive coating to initiate curing, exposing the second adhesive coating to ultraviolet light to continue curing, laminating a third lens (or stack of lenses) onto a surface of the second adhesive coating to add the third lens to the stack of lenses, and exposing the stack of lenses to an electron beam to continue curing of the first and second adhesive coatings.