Plastic Reflective Coating Stack for Crack-Resistant Lens Assemblies
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Solution Overview
Problem
Conventional reflective coating membranes in optical lens assemblies suffer from cracks and defects due to improper material arrangement and environmental factors, and they exhibit insufficient reflectivity in both visible and infrared regions, failing to meet required reflectivity standards.
Innovation Solution
An optical lens assembly with a reflective element made of plastic material, featuring a reflective coating membrane composed of at least three layers: silver, titanium, and chromium oxides, arranged in specific configurations to enhance reflectivity and prevent cracking, with additional layers like silicon compounds for protection and improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reflective coating membrane is applied on a plastic reflective element, then the reflectivity can be improved, but the coating membrane becomes prone to cracks and defects due to environmental factors and improper material arrangement
Solution Approach 1:
The patent applies a multi-layer composite coating structure consisting of a plastic layer, silver layer, aluminum oxide layer, and protective layer. This composite material approach combines the high reflectivity of silver with the protective properties of aluminum oxide and the adhesion benefits of the plastic substrate, resolving the contradiction between achieving high reflectivity and maintaining coating integrity under environmental stress
Solution Approach 2:
The patent introduces intermediate layers (plastic layer and aluminum oxide layer) between the silver reflective layer and the external environment. These intermediary layers act as buffers that prevent direct exposure of the silver to environmental factors causing cracks, while also providing thermal expansion mismatch mitigation and mechanical protection, thus maintaining coating membrane integrity
2Ease of manufacture
If conventional reflective coating membranes are used, then the manufacturing process is simple, but the reflectivity in visible and infrared regions is insufficient and cannot meet required standards
Solution Approach 1:
The patent employs a multi-layer composite coating system with specific material selections (silver for reflectivity, aluminum oxide for protection, plastic for adhesion) that can be deposited using conventional vacuum coating techniques. This approach maintains manufacturing simplicity while achieving superior reflectivity performance in both visible and infrared regions through the synergistic properties of the composite structure
Solution Approach 2:
The patent optimizes the thickness parameters of each coating layer to achieve maximum reflectivity. By controlling the thickness of the silver layer, aluminum oxide layer, and plastic layer within specific ranges, the coating system achieves enhanced reflectivity across broad spectral regions while remaining compatible with standard manufacturing processes
3Device complexity
If the reflective coating membrane is made with fewer layers, then the manufacturing complexity is reduced, but the durability against oxidation and cracking is insufficient
Solution Approach 1:
The patent implements a four-layer composite coating structure (plastic, silver, aluminum oxide, and protective layers) where each layer serves a specific function. This structured composite approach provides systematic protection against oxidation and cracking while maintaining manageable manufacturing complexity through established multi-layer deposition techniques
Solution Approach 2:
The patent incorporates protective layers (aluminum oxide and outer protective layer) beforehand to cushion and prevent environmental damage to the underlying silver reflective layer. This prior cushioning approach proactively prevents oxidation and cracking before they can occur, enhancing coating durability without significantly increasing manufacturing complexity
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 solution achieves high reflectivity in the visible and near-infrared ranges, preventing cracks and oxidation, enabling miniaturization and image stabilization while maintaining high precision and cost efficiency.
Implementation Method 1
the reflective element includes a reflective coating membrane, and the reflective coating membrane is disposed on a surface of the reflective element. The reflective coating membrane includes at least three coating layers of different materials... When an average reflectance in a wavelength range of 800 nm-1000 nm of the reflective coating membrane is R80100, the following condition is satisfied: 97.5%≤R80100
Implementation Method 2
the coating layer made of the first material and the coating layer made of the second material are disposed between the coating layer made of the third material and the reflective element... the third material mainly includes chromium oxides
Data Source
AI summary
According to the present disclosure, an optical lens assembly includes at least two optical lens elements and at least one reflective element. The reflective element is made of a plastic material, the reflective element includes a reflective coating membrane, and the reflective coating membrane is disposed on a surface of the reflective element. The reflective coating membrane includes at least three coating layers of different materials, the at least three coating layers are respectively made of a first material, a second material and a third material, the first material mainly includes silver, the second material mainly includes titanium, the third material mainly includes chromium oxides, and the coating layer made of the first material and the coating layer made of the second material are disposed between the coating layer made of the third material and the reflective element.