Polyamide Functional Sheet Air Bubble Reduction
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Solution Overview
Problem
The generation of air bubbles during the manufacturing of polyamide resin sheets for sunglasses, which impairs the appearance and is difficult to prevent in industrial manufacturing due to the high gas barrier properties of polyamide resin, causing issues with the adhesive and functional layers.
Innovation Solution
A polyamide functional sheet with a protective layer formed by a polyamide resin having an oxygen transmission rate of 50 cm3/m2·24 hr·bar or more, using a non-crystalline or microcrystalline polyamide and a urethane resin solvent-based adhesive, and controlling the retardation of the protective layer to 200 nm or less or 2,000 nm or more, to reduce or eliminate air bubble generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polyamide resin sheet is used as a protective layer, then chemical resistance is improved, but air bubbles are generated that impair the appearance
Solution Approach 1:
The patent changes the oxygen transmission rate parameter of the polyamide resin from high (comparative example) to low (50 cm³/m2·24 hr·bar or more), which prevents gas accumulation and air bubble formation while maintaining chemical resistance
Solution Approach 2:
The patent introduces an adhesive layer as an intermediary between the polyamide protective layer and the functional layer, using a urethane resin solvent-based adhesive that is compatible with polyamide and does not generate excessive gas during curing
2Manufacturing precision
If the oxygen transmission rate of polyamide resin is increased, then air bubble generation is reduced, but gas barrier properties are compromised
Solution Approach 1:
The patent optimizes the oxygen transmission rate to a specific range (50 cm³/m2·24 hr·bar or more) that balances gas permeability for manufacturing quality with gas barrier properties for product performance
Solution Approach 2:
The patent applies different quality requirements to different aspects: higher oxygen transmission is allowed during manufacturing to prevent bubbles, while the adhesive layer provides the primary gas barrier function for the finished product
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 effectively reduces or eliminates air bubble formation, ensuring a stable manufacturing process and maintaining the quality of the polyamide functional lens, suitable for industrial production.
Implementation Method 1
it becomes clear that the polyamide resin sheet has higher gas barrier properties than the aromatic polycarbonate sheet as shown in a low oxygen transmission rate
Data Source
AI summary
Provided is a functional polyamide sheet in which air bubbles are not generated or are reduced in a polarizing and/or photochromic functional sheet when the polarizing and/or photochromic functional sheet are/is manufactured using a sheet or film formed by a polyamide resin as a protective layer, and a functional polyamide lens using the functional polyamide sheet.Provided are a polyamide functional sheet obtained by disposing a protective layer formed by a transparent plastic sheet or film on at least one surface of a functional layer, which is a polyvinyl alcohol-based polarizing film layer, a photochromic layer, or a combination of these layers, with an adhesive layer being interposed therebetween, in which the protective layer is a sheet or film formed by a polyamide resin, and an oxygen transmission rate at 23° C. and 85% RH is 50 cm3/m2·24 hr·bar or more, and a functional polyamide lens using the polyamide functional sheet.