Polarization Conversion Element UV-Curing Adhesive
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Solution Overview
Problem
Conventional polarization conversion elements in liquid crystal projectors face issues with adhesive degradation under high-luminance light sources, leading to reduced transmittance and increased thermal load, and alternative configurations that avoid adhesives result in complex manufacturing processes and increased size.
Innovation Solution
A polarization conversion element using an ultraviolet-curing resin adhesive with superior heat and light resistance, and a phase difference plate formed by intersecting quartz crystal wave plates, which are bonded using a plasma polymerized film or atomic diffusion method, ensuring reliable polarization conversion without adhesive degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional organic adhesive is used to bond light transmitting substrates, then the manufacturing process is simple, but the adhesive degrades under high-luminance light sources leading to reduced transmittance and increased thermal load
Solution Approach 1:
The patent changes the chemical composition parameters of the adhesive from conventional organic adhesive to ultraviolet-curing resin adhesive, which has superior heat and light resistance. This parameter change enables the adhesive to maintain stability under high-luminance light sources while preserving the bonding function, thus resolving the contradiction between manufacturing simplicity and adhesive reliability.
Solution Approach 2:
The patent uses composite material approach by combining ultraviolet-curing resin with specific additives to create an adhesive formulation that exhibits both ease of application and superior resistance to heat and light. The composite adhesive maintains the simplicity of the bonding process while achieving enhanced reliability under high-luminance conditions.
2Reliability
If quartz crystal wave plates are bonded using plasma polymerized film or atomic diffusion method, then heat and light resistance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent replaces conventional mechanical bonding methods with plasma polymerized film or atomic diffusion methods for bonding quartz crystal wave plates. This substitution enables the bonded structure to achieve superior heat and light resistance while the processes are integrated into the existing manufacturing workflow, minimizing the increase in manufacturing complexity.
3Strength
If adhesive layer thickness is increased to improve bonding strength, then bonding reliability is improved, but light transmittance is reduced due to increased absorption
Solution Approach 1:
The patent changes the material parameters of the adhesive to ultraviolet-curing resin, which has lower light absorption characteristics. This enables the use of thicker adhesive layers for improved bonding strength while minimizing the negative impact on light transmittance, thus resolving the contradiction between bonding strength and light energy loss.
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 provides a polarization conversion element with high heat and light resistance, maintaining optical performance and extending lifespan while simplifying the manufacturing process and reducing size.
Implementation Method 1
an ultraviolet-curing resin adhesive having a thickness equal to or larger than 5 μm and equal to or less than 10 μm
Implementation Method 2
a phase difference plate that is arranged on the light outgoing face, converts any one of the two types of linearly-polarized light beams into a linearly-polarized light beam parallel to a polarization plane of the other linearly-polarized light beams by rotating a polarization plane
Implementation Method 3
bonded using a plasma polymerized film
Implementation Method 4
bonded using an atomic diffusion method
Data Source
AI summary
In a polarization conversion element including a plurality of light transmitting substrates and an optical element that includes polarization splitting films and reflective films that are alternately disposed between the light transmitting substrates, and a laminated wave plate that is arranged on the light outgoing face of the optical element and rotates the polarization plane of light emitted from the optical element by θ, a laminated wave plate is acquired by stacking a first wave plate of a phase difference Γ1 for light of a wavelength λ and a second wave plate of a phase difference of Γ2 such that the optical axes thereof intersect each other, the relationship is “|Γ1−Γ2|=180 (degrees), and the azimuth of the optical axis of the first wave plate and the azimuth of the optical axis of the second wave plate are perpendicular to each other.