Polarizing Optical Element Manufacturing via Inflatable Membrane Pressing
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Solution Overview
Problem
Current methods for producing polarizing optical elements, such as ophthalmic lenses, often require complex processes involving sandwiching polarizing films between polymer layers and heating steps, which can alter the dioptric and colorimetric properties, and are not suitable for on-demand production outside centralized factories.
Innovation Solution
A method involving a layered structure with a first orientation layer of photo-oriented polymers and a second polarizing layer with liquid crystal monomers and dichroic dyes, applied to a base optical element using a pressing device with an inflatable membrane, allowing for a thin, flexible, and adhesive bonding process without heating, enabling production on demand and compatibility with varying optical element curvatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If casting processes are used to produce polarizing thermoset lenses by sandwiching polarizing films between polymer layers, then the polarizing function is achieved, but the dioptric and colorimetric properties are altered due to heating steps
Solution Approach 1:
The patent replaces thermal heating processes with a mechanical pressing process. Instead of using heat to bond the polarizing layer to the optical element, the invention uses a pressing device with an inflatable membrane to apply mechanical pressure, thereby avoiding thermal alteration of the dioptric and colorimetric properties while achieving reliable polarizing function.
Solution Approach 2:
The patent introduces an adhesive layer as an intermediary between the polarizing layer and the optical element. This adhesive mediator enables bonding without direct thermal contact, allowing the polarizing layer to be attached to the optical element surface without subjecting the optical element to heating that would alter its properties.
2Manufacturing precision
If centralized factory production is used for polarizing optical elements, then manufacturing precision is maintained, but production flexibility and on-demand capability are reduced
Solution Approach 1:
The patent segments the production process into two independent parts: manufacturing the base optical element and applying the polarizing layer. The polarizing layer can be pre-prepared on a support and then applied to completed optical elements, allowing decentralized production at prescription laboratories while maintaining quality control through standardized adhesive bonding procedures.
Solution Approach 2:
The patent enables preliminary preparation of the polarizing layer structure on a support before application to the optical element. This preliminary action allows the polarizing functionality to be manufactured in advance with quality control, then applied on-demand to specific optical elements at prescription laboratories, combining centralized manufacturing precision with decentralized flexibility.
3Reliability
If thick polarizing layers are used to ensure polarizing function, then polarization contrast is improved, but optical element thickness and weight increase
Solution Approach 1:
The patent changes the physical state and orientation parameters of the liquid crystal molecules in the polarizing layer. By controlling the angular orientation of liquid crystal molecules through the adhesive layer's properties, the patent achieves effective polarizing function with thinner layers, as the polarization contrast is generated through molecular orientation rather than layer thickness.
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 method produces polarizing optical elements with high optical quality and polarization contrast, compatible with ophthalmic use, while reducing production complexity and enabling on-demand manufacturing without altering the dioptric or colorimetric properties, and can be applied to optical elements with different chemical compositions and curvatures.
Implementation Method 1
pressing the layered structure against the surface of the base optical element by inflating the membrane
Implementation Method 2
The layered structure is thus bonded to the base optical element, via the portion of adhesive material
Data Source
AI summary
The method involves forming a polarizing layer structure (30), with a orientation layer, on a film support (31), and placing a ophthalmic glass (40) and the structure between support surface pressing and inflatable pressing devices (10, 20). A portion of an adhesive material is arranged between the structure and the glass. The structure is pressed against a surface of the glass by inflating a membrane of the device (20) and by maintaining a fixed space between the devices. The ophthalmic glass is released and the support is withdrawn so that the structure is stick on the surface. Independent claims are also included for the following: (1) a layer structure comprising a orientation layer (2) a polarizing optical element comprising an optical base element and a layer structure.