Polarizing Lens Manufacturing via Mold Taping and Resin Polymerization

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Solution Overview

Problem

Conventional methods for manufacturing polarizing lenses are complex and burdensome due to the requirement for gasket molds, zigs, stands, and notch formation, which complicates the process and increases costs.

Innovation Solution

A method involving taping molds with thermal-resistant tape, applying resin compositions, and performing polymerization at specific temperatures and times to form polarizing lenses without the need for lower and upper zigs, stands, and notches, simplifying the process and eliminating the use of gasket molds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods using gasket molds, zigs, stands, and notch formation are employed, then polarizing lenses can be manufactured, but the process becomes complex and burdensome

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidequipment complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent extracts and removes the unnecessary auxiliary components (gasket molds, zigs, stands, and notch formation steps) from the manufacturing process. By eliminating these extraneous elements, the process is simplified while maintaining the core functionality of producing polarizing lenses with precise thickness control

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The manufacturing process is segmented into distinct stages: forming the first resin composition layer with the polarizing film, spacing the molds to create a cavity, and injecting the second resin composition. This segmentation allows each step to be optimized independently, reducing overall process complexity

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If gasket molds and zigs are used in the manufacturing process, then lens thickness can be controlled, but manufacturing costs increase

Engineering Contradiction:

Improvelens thickness controlVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The mold structure itself provides the thickness control function that previously required separate gasket molds and zigs. By designing the mold cavity with precise dimensions and using the resin composition to fill and cure within this cavity, the system achieves self-contained thickness control without additional expensive components

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent changes the approach from mechanical thickness control (using physical gaskets and zigs) to chemical/volumetric control (using the volume of resin composition injected and the cavity dimensions). This parameter change eliminates the need for expensive mechanical thickness-control components

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If notch formation is performed on the polarizing film, then lens assembly is enabled, but the process becomes more complicated

Engineering Contradiction:

Improvelens assembly easeVSAvoidprocess complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The mold cavity is pre-designed with the necessary features to accommodate the polarizing film and enable assembly without requiring notches to be cut into the film. The preliminary preparation of the mold structure eliminates the need for subsequent notch formation and assembly operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of modifying the polarizing film (cutting notches) to enable assembly, the approach is inverted: the mold cavity is designed to accommodate the intact polarizing film and guide its positioning. This inversion eliminates the need for film modification while achieving the same assembly objective

Inventive Principle:

Principle #13The other way round (Inversion)

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 increases work efficiency and reduces manufacturing costs by eliminating the need for complex equipment and notch formation, while enabling the production of high-refractive polarizing lenses with improved thickness and refractive index.

Implementation Method 1

performing first polymerization on the upper mold including the first resin composition and the polarizing film

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 2

performing second polymerization on the upper mold including the gel-state upper lens coupled with the polarizing lens, the second resin composition, and the lower mold

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Implementation Method 3

taping an upper mold using first tape

Methodology Applied

Scientific EffectThermal resistance: Thermal Insulation

Data Source

PatentUS9579857B2Method for manufacturing polarizing lens and polarizing lens manufactured by the same

Publication Date: 2017.02.28 OMEGA OPTICS

AI summary

A method for manufacturing a polarizing lens comprises taping an upper mold using first tape, applying a first resin composition onto a concave surface of the upper mold, forming a polarizing film on the first resin composition, performing first polymerization on the upper mold including the first resin composition and the polarizing film, spacing the upper mold apart from a lower mold, taping the upper mold and the lower mold using second tape, injecting a second resin composition into a space between the polarizing lens and the lower mold, and performing second polymerization on the upper mold including the gel-state upper lens coupled with the polarizing lens, the second resin composition, and the lower mold.